Tir A8 16

A M E RCopyright
Irepublished
Cby theAFenestration
N andA RIndustry
Glazing C Alliance
H (FGIA).
I TIt may EnotC T U R A L
be reproduced,
or distributed in any format without the express written consent of FGIA.
AAMA TIR-A8-16
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
Copyright by the Fenestration and Glazing Industry Alliance (FGIA). It may not be reproduced,
republished or distributed in any format without the express written consent of FGIA.

1.0 FOREWORD ............................................................................................... 1
2.0 INTRODUCTION ......................................................................................... 1
3.0 THERMAL BARRIER MATERIALS............................................................ 4
4.0 DESIGN GUIDELINES ................................................................................ 5
5.0 ENVIRONMENTAL IMPACT .................................................................... 22
6.0 TESTING ................................................................................................... 23
7.0 APPENDICES ........................................................................................... 33
8.0 ATTACHMENTS ....................................................................................... 61
9.0 REFERENCES .......................................................................................... 70
AAMA is the source of performance standards, products certification and

educational programs for the fenestration industry.SM
All AAMA documents may be ordered at our web site in the “Publications Store”.
©2016 American Architectural Manufacturers Association – These printed or electronic

pages may NOT be reproduced, republished or distributed in any format without the
express written consent of the American Architectural Manufacturers Association.
This document was developed and maintained by representative members of AAMA

as advisory information. AAMA DISCLAIMS ALL WARRANTIES WITH REGARD TO
THIS INFORMATION, INCLUDING ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS. IN NO EVENT SHALL AAMA BE LIABLE FOR
ANY DAMAGES WHATSOEVER FROM THE USE, APPLICATION OR ADAPTATION
OF MATERIALS PUBLISHED HEREIN. It is the sole responsibility of the
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information, opinion, advice or other content published herein.
AAMA TIR-A8-16
ORIGINALLY PUBLISHED: 1990
PRECEDING DOCUMENT: TIR-A8-08
PUBLISHED: 9/16
American Architectural Manufacturers Association

1827 Walden Office Square, Suite 550, Schaumburg, IL 60173
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EMAIL webmaster@aamanet.org WEBSITE www.aamanet.org
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
energy through an architectural framing system is reduced. This interruption of energy flow has obvious benefits in substantially
reducing the total energy consumption of the building of which the end product is a part. The thermal barrier will also effectively
improve the resistance of the framing members to condensation or frost formation. These thermal barrier systems allow aluminum to
provide thermal performance comparable with other framing materials.
Though there are several thermal barrier systems 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 The primary units of measure in this document are metric. The values stated in SI units are to be regarded as the standard. The
values given in parentheses are for reference only.
2.2 This document was developed in an open and consensus process and is maintained by representative members of AAMA as
advisory information.
2.3 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 by a structural thermal barrier material to improve the thermal performance of the composite section.
FIGURE 1 – Typical Poured and Debridged Thermal Barrier Aluminum Extrusion
2.3.1 Definition of Poured and Debridged Design
An aluminum composite framing member, consisting of single extruded aluminum sections separated by a thermoset material providing
a structural thermal barrier. The thermoset material is poured into the cavity of the extrusion. After curing, the extruded bridge is
removed. The resultant framing member is a composite member consisting of interior and exterior aluminum sections separated by a
structural, insulating thermal barrier. (See Figures 1, 2a and 2b).
AAMA TIR-A8-16 Page 1

FIGURE 2a: Typical Poured and Debridged Single Cavity Thermal Barrier Composite Profile
FIGURE 2b: Typical Poured and Debridged Dual Cavity Thermal Barrier Composite Profile
2.3.2 Definition of Mechanically Locked Design
An aluminum composite framing member, consisting of individual interior and exterior extruded aluminum sections separated by a
preformed thermal barrier. First, both the interior and exterior aluminum extrusions are knurled. The structural thermal barrier
material is then inserted into the knurled extruded cavity of both the interior and exterior portions and after rolling (crimping) the
mechanical locking process is complete. (See Figures 3 and 4).
FIGURE 3: Typical Mechanically Crimped In Place Thermal Barrier Extrusions

FIGURE 4: Typical Mechanically Crimped In Place Thermal Barrier Composite Section
2.4 History
Throughout the world, aluminum extrusions have become the preferred construction material for windows and doors. The reasons for
the popularity of aluminum are many. Aluminum extrusions are lightweight with one of the highest strength to weight ratios of any
material. For the designer, they offer an unlimited variety of shapes. They are produced at close dimensional tolerances, providing for
excellent operational fit and structural stability. Aluminum is not subject to warping, rust or vermin damage. Aluminum accepts many
finishes allowing for a wide variety of color applications. Aluminum is the most recycled material used for framing.
However aluminum is one of the most thermally conductive metals. This high thermal conductance has been a cause of concern related
to the use of aluminum in fenestration products, principally energy loss and associated condensation. In response to these concerns,
designers have devised methods to separate the 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.
2.4.1 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 resulted in the first
window product to be 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.
2.4.2 History of Mechanically Locking Thermal Barriers
The mechanical locking thermal barrier system originated in Europe in the early 1970’s, by 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 United States. These windows went into service in the spring of 1991 and are still in service as of the date of
this printing.
Along with the advancements in insulating glass, improved sealants, weather stripping and high performance finishes, thermal barriers
have provided a great impetus for the growth of aluminum as the preferred material for architectural framing. Since the early seventies,
thermal barriers have achieved such universal acceptance that they are now considered a standard way to produce energy efficient
fenestration framing products.
To ensure continued reliability and technical improvements of thermal barriers, AAMA organized the Thermal Barrier Structural Task
Group at its October 1981 Annual Meeting. This committee was comprised of experts in the field, including design engineers, process
engineers, corporate and marketing managers and chemists. It was decided at this meeting that the main responsibility of the task group
would be to prepare a Technical Information Report (TIR) for the manufacturers of windows, doors, curtain walls, storefronts, skylights
and other glazed architectural products that would establish guidelines, performance standards, processing recommendations and test
methods for thermal barriers.

Given the significant innovations and changes in thermal barrier design, AAMA charged the Thermal Barrier Task Group to update the
current TIR-A8-90. The mission of the Task Group was to revise and expand the TIR-A8-90 document to include innovations in
products and testing. This document is the result of that effort.
2.5 Effect on Condensation Resistance Factor (Crf) and Thermal Transmittance (U-factor)
The thermal barrier serves to isolate the aluminum on the exterior of the framing system from the aluminum on the interior. A properly
designed system will still maintain the structural integrity of the framing while not permitting a thermal short circuit between exterior
and interior metal.
A thermal barrier provides an effective method of limiting the formation of condensation and frost on the interior frame. Condensation
at this point can damage interior trim and wall covering or at the very least be a nuisance to the building owner. The ability of a framing
system to resist condensation formation is expressed by the Condensation Resistance Factor (CRF). AAMA document 1503, “Voluntary
Test Method for Thermal Transmittance and Condensation Resistance of Windows, Doors and Glazed Wall Systems” provides
guidance to the design professional on determining the proper Condensation Resistance Factor requirements for a project. In general,
framing systems with thermal barriers have significantly better condensation resistance than those without.
Like CRF, the coefficient of thermal transmittance (U-factor) for the glazed framing system will also improve when thermally broken
sections are utilized. The thermal barrier effectively reduces the amount of heat transfer from one side of the extrusion to the other. The
effect of thermal sections on the U-factor of the composite glazed product will depend upon the ratio of the metal area to the glass area.
3.0 THERMAL BARRIER MATERIALS

Any material that improves the thermal performance of an aluminum window frame without compromising the structural integrity of the
window may be used as a thermal barrier. All products used for thermal barrier applications must have a set of minimum performance
properties. Properties such as tensile strength, elongation, impact resistance, thermal conductivity, flexural modulus, adhesion properties
and heat deflection temperatures should all be considered during the design and application stage.
After reviewing all of the technical data, a product that meets the general product parameters should be selected and then run under
typical plant conditions in extrusions designed for the particular application. Samples of these extrusions should then be tested to
confirm that the product will perform to the expected level.
Regardless of the type of thermal barrier product or material chosen, care must be taken in its design and application as the performance
properties needed for each application can vary significantly. The manufacturer should be consulted throughout all aspects of this
process. This remains the key to the success of any product chosen.
It is important to note that an excellent material will not perform in a poorly designed thermal barrier cavity, nor will a poor material
perform in a properly designed cavity. Both the cavity design and the material must be correct. In this specification we will discuss two
thermal barrier materials, one being a poured urethane (a mix of two components, used in a poured-and-debridged system) and the other
being a preformed, engineered profile extruded into a thermal barrier shape. There are other materials that may be used as composite
thermal barrier materials but they will not be discussed here in detail; however the analytical procedures in this document would still be
applicable.
The final thermally separated composite extrusion must exhibit the following properties:
1. Resistance to deflection must be adequate to meet the requirements of the intended application at the anticipated loads and
ambient conditions.
2. Resistance to torsion must be greater than the expected forces caused by the loads on the frame.
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 the weight of the glazing material or hardware hung on the window.
6. It must be designed so as to minimize dry shrinkage. (If applicable.)
7. Resistance to distortion and impact loading must be adequate to the end use of the product.
4.0 DESIGN GUIDELINES

4.1 Material Selection
The information contained in this section is garnered from the shared experiences of AAMA members involved in supplying and/or
manufacturing of thermal barrier products. They are not intended to be prescriptive or all inclusive. Commonly accepted engineering
practices should be followed in the design of any component of a framing system.
Following are cavity design guidelines for structural thermal barrier sections. These 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.
4.1.1 Poured in Place Cavity Design
Only single profile thermal barrier cavities of general shape shown in Figures 5 to 9 are addressed. Design criteria range from
thermal to structural to extrudability which are often at odds with each other, and are summarized as follows:
1. Maintain an appropriate width-to-depth ratio on cavity dimensions as shown in Figure 8. This helps promote good flow into
the cavity during pouring and develops optimum structural strength in tension and torsion for any given amount of thermal
barrier material. Unusual profiles may involve significant deviations in structural integrity. In addition the design must stay
within extrudability limits of the aluminum by employing gap width ratios (cavity area divided by the square of the gap width)
less than 3.5.
FIGURE 5: Poured in Place Cavity Design
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: Pour and Fill
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: Pour and Fill
In removing the bridge avoid irregular cuts or cutting too deep as shown in Figures 6C, 6D and 7C as this will weaken the
structural integrity of the thermal barrier. Failure to fully remove the bridge as shown in Figure 6E may affect the thermal
transmittance of the section and may cause clearance problems as shown in Figures 7D and 7E.
3. All interior corners of the cavity should be radiused 0.8 mm (1/32 in) minimum as shown in Figure 8.
These radii help eliminate voids and pin holes in the fluid during the viscous flow pouring process.
POUR SIDE
EXTRUSION GAP
RADIUSED
CORNERS
RETENTION
LUGS FOR MECHANICAL INTERLOCK
WITH THERMAL BARRIER MATERIAL
EXTRUDED CAVITY
FIGURE 8: Extruded Cavity
4. Provide a "fluid head" to force the viscous fluid into all recesses of the cavity when pouring.
5. Keep the thermal barrier cavity profile symmetric whenever practical. This avoids eccentric loading in tension and torsion.
6. Ensure that the cross-sectional profile and location of the thermal barrier cavity does not create thermal "short circuits" at
joinery whenever practical. In doing this, the basic design of the system must be reviewed, i.e., square cut vs. mitered
construction, etc.
7. In situations where sections are dependent on adhesion for shear strength, maximize the surface area within the cavity.
Greater surface area will result in lower shear stresses being developed at the bond line during flexure. Surface treatment is
addressed in Section 4.2.
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 instances, a thermal barrier location yielding
optimal condensation resistance will not yield the lowest possible frame U-factor. Thermal barrier location near the exterior
minimizes the possibility of hardware "short circuits" resulting in better thermal performance.
10. Position the thermal barrier to avoid direct exposure to the elements. This assures thermal integrity, avoids appearance
problems and minimizes the possibility of ultraviolet degradation.
11. Cavities smaller than those shown in Figure 9 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.

FIGURE 9: Standard and Conceptual Cavity Designs and Data

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.
4.1.2 Mechanically Locked, Preformed Thermal Barriers, Cavity Design
The cavity shown in Figure 10 is for a single thermal barrier strut. Normal use of mechanical locking thermal barrier systems has the
profiles being used in pairs. This allows for one thermal strut to be in compression and the other in tension to provide the maximum
strength for fenestration products.
FIGURE 10: Typical Thermal Barrier Cavity
The cavity allows for the structural thermal barrier to be inserted into the aluminum extrusion. The design of the cavity is slightly
oversized to allow for the knurling of the sidewalls before the profile is inserted. The profile can be inserted into the aluminum either
by hand or by an insertion machine.
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
Before the thermal barrier is inserted into the aluminum extrusion both the interior and exterior sides of the extrusion need to be
knurled. The key to the strength of a mechanical locking, pre-formed thermal barrier system is a proper knurl on the aluminum
extrusions. A proper knurl will have sharp edges that allow the notches to be rolled into the thermal barrier to make contact and hold
it in place. A knurling machine is used to place notches on the aluminum extrusion. Figure 11 shows the difference between a proper
and an incorrect knurl on the aluminum cavity.
INCORRECT PROPER
FIGURE 11: Knurl on the Aluminum Cavity
Besides having a knurling on both sides of the aluminum cavity, the knurling needs to be of equal depth on both sides of the cavity.
Unequal knurling on the two sides of the aluminum cavity will produce inconsistent shear strength values across the aluminum
assembly. Also, uneven knurling will create problems inserting the thermal barrier into its pocket. The knurling being too deep on
the one side will grab the thermal barrier and not allow for the thermal barrier to be inserted into the aluminum cavity whether it be
inserted by hand or machine.

Inserting the Thermal Barrier into the Aluminum Cavity
The thermal barrier is inserted into the pocket in the aluminum cavity by sliding it in from one end of the extrusion. This can be done
by hand or by machine, one profile at a time or both at the same time. The degree of difficulty in inserting the thermal barrier into its
cavity depends on the depth of the knurling in the cavity.
An aluminum extrusion without sufficient knurling will allow for the thermal barrier to be inserted very easily. The knurling will not
provide any resistance in sliding the thermal barrier profiles into the respective aluminum cavities. However, without the proper
knurling on the aluminum cavity a high shear strength value for the aluminum extrusion with a thermal barrier cannot be achieved.
However, an aluminum extrusion with the knurling too deep will not allow for the thermal barrier to be inserted 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 crimping process on the
aluminum extrusion.
Rolling of the Aluminum-Thermal Barrier Composite
After the Thermal Barriers (2) have been inserted between the two halves of the aluminum extrusion, the assembly is now ready for
the rolling process. The mechanical lock is created when the aluminum cavity passes between the rolling discs and the “hammer” on
the aluminum is forced into the thermal barrier.
When rolling the aluminum composite, the window manufacturer needs to be sure there is enough pressure on the rolling wheels to
create the mechanical lock between the thermal barrier and the aluminum extrusion. The fabricator should consult the instruction
manual on his specific insertion equipment for setting up the machine to ensure the rolling machine will crimp the aluminum with
enough force to create the necessary shear strength for your fenestration products.
Also, the rolling wheels need to be properly aligned on 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: Crimping Roller Alignment
After the rolling of the aluminum extrusion, the profile is ready for use. Random testing of the assembly is recommended to ensure
the quality and consistency of the insertion process.
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.

4.1.3 Shrinkage
Some thermal barrier systems can experience two kinds of shrinkage, wet and dry. Wet shrinkage is the end-to-end shrinkage of freshly
poured material as it gels, sets up and cools within the extrusion. Dry shrinkage is the end-to-end contraction of the thermal barrier after
the composite section has been cut to size. Dry shrinkage may occur after the composite has experienced repeated thermal cycling.
4.1.3.1 Poured and Debridged Shrinkage
There are a number of factors that are known to contribute to wet shrinkage. These factors are gel time, peak exotherm temperature
reached by the resin in the cavity, cavity size, extrusion mass, and the temperatures of the resin and the aluminum at the time of pouring.
These factors are also dependent on the specific resin formulation used. Physically, what happens is the material in the center of the
pour solidifies faster than the material near the walls of the aluminum cavity. This is due to a lower temperature at the channel wall
created by the heat sink effect of the aluminum. The rate of cure, or speed of solidification, is temperature dependent. The hotter the
temperature is, the faster the cure. As a result, the material near the channel remains more fluid than the core material and permits
wet shrinkage to occur. Advances in urethane resin formulations have reduced the potential for wet shrinkage.
When dry shrinkage occurs, it is a result of poor adhesion of the thermal barrier to the substrate with which it is in contact. Dry
shrinkage is an end-to-end exposure of cavity walls after curing and thermal cycling. Typically, the cut end of the thermal barrier, which
is initially flush with the end of the extrusion cavity, pulls back or retracts evenly leaving a gap at the end. No thermal barrier material is
apparent on the exposed cavity walls, hence the term ‘dry shrinkage’. Since dry shrinkage occurs after the extrusion is cut and fabricated
into window and door units, gaps could open up at the corners causing water and air leakage.
Dry shrinkage will typically occur after repeated exposure to environmental cycling. The large difference in coefficients of thermal
expansion, between the aluminum and the thermal barrier, is one factor that creates stresses that can initiate dry shrinkage. Aluminum
has a coefficient of thermal expansion of 2.3 x 10-5 mm/mm • °C (1.3 x 10-5 in/in • °F) while typical thermal barrier resins are of 9.0 to
12.6 x 10-5 mm/mm • °C (5 to 7 x 10-5 in/in • °F) or four to five times more than aluminum. As a result, the thermal barrier attempts to
change dimensions more than the aluminum with the same temperature changes. At elevated temperatures the thermal barrier tries to
expand more than the surrounding aluminum while at lower temperatures the thermal barrier will try to contract more. A second factor,
which could affect dry shrinkage, is the temperature difference between the exterior and interior aluminum facing sections. There are
ways to eliminate the potential for dry shrinkage. Surface preparation, mechanical staking, chemical adhesion, and proper selection
of finish and surface treatments are the primary ways to avoid dry shrinkage. Conditions that promote dry shrinkage are cavity
surfaces contaminated with grease, oil, dirt or die lubricants, metal surface pretreatments and seal coats that do not achieve adequate
adhesion to the aluminum, or thermal barrier material that does not adhere to the finish. For a discussion of finishes see 4.2.1.
Generally, dry shrinkage has always been attributed to the thermal barrier. The critical role of proper seal coat and finish selection
and preparation cannot be ignored. Typically, finishes have coefficients of thermal expansion closer to the thermal barrier than the
aluminum. If there is poor adhesion of the finish to the metal, dry shrinkage will occur as the bond fails at the finish-metal interface.
Cavity design also influences the potential for dry shrinkage. Some designs are more resistant to shrinkage than others. When in doubt,
the framing designer or manufacturer should consult the thermal barrier resin supplier about shrinkage.
4.1.3.2 Mechanical Locking Shrinkage
Mechanical Locking Thermal Barrier Systems do not experience either wet or dry shrinkage. In terms of wet shrinkage, the
mechanical locking thermal barrier is usually an extruded engineering plastic that does not have a set up or gel time. The material is
extruded to shape and then installed in the fenestration product.
The dry shrinkage problem occurs over thermal cycling of the fenestration product. The material chosen for the mechanical locking
thermal barrier will determine if there will be any dry shrinkage. In cases, where the mechanical locking thermal barriers are glass-
reinforced polyamides, there will not be any dry shrinkage. Glass reinforced polyamides have a coefficient of thermal expansion
almost identical to aluminum. This results in expansion and contraction of the thermal barrier and the aluminum at the same rate
during thermal cycling. This results in no dry shrinkage in a mechanical locking thermal barrier system.
4.1.3.3 Aluminum Cavity Distortion
Distortion can be the result of a number of contributing factors:
1. Cavity size and shape

2. Metal thickness of the cavity walls
3. Extrusion design
4. Processing parameters
FIGURE 13: Mechanical Locking
4.1.3.4 Mechanical Locking Distortion of Aluminum
During the crimping process the aluminum extrusion can be distorted. However, the affects of the distortion are negligible if the
insertion process is done properly. Most crimping machines provide three specific steps within the crimping process.
Step 1 – Straightening of the aluminum composite with the thermal barrier installed
After the thermal barrier is inserted in the aluminum extrusions the composite section is ready for the crimping process. The
first step in crimping is to align the composite section to ensure it is in the right position to complete the crimping process.
Step 2 – Crimping of the Aluminum Extrusions
Once the profile is aligned properly, it is ready to pass through the main crimping stage. This is where the mechanical lock
between the thermal barrier and the aluminum extrusions is actually created. During this stage, the hammer side of the
aluminum extrusion is pushed into the thermal barrier profiles creating the lock between the aluminum and the thermal barrier.
Step 3 – Profile Correction Stage
The final stage of the crimping process is the correction stage to ensure that the aluminum is not distorted during the crimping
process. The final stage ensures that the aluminum is straight in both the up and down direction and the left right direction. This
ensures that the fenestration product will be able to be manufactured from the aluminum lineal containing the thermal barrier.
Over crimping in stage 2 could also cause distortion to the aluminum cavity. The window manufacturer needs to be sure that
they are following the insertion equipment instructions on the crimping of the aluminum extrusions to ensure that they are not
applying to much pressure during the crimping which could distort the aluminum cavity.
Finally, in a mechanically crimped thermal barrier system, the aluminum cavity is always changed during the crimping
process. The initial design of the aluminum cavity should take this in account so that the aluminum cavity after crimping will
allow for the fenestration product to be manufactured into its finished dimensions.
4.2 Cavity Surface Treatment
The cavity should be clean, dry and oil-free before installing the thermal barrier material.
4.2.1 Poured in Place Materials
Most designs rely on adhesion between polyurethane and 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 and project requirements, the surface treatment present on interior cavity surfaces
can vary widely from one manufacturer, project or section to another. It is important that all possible surface treatments be tested for
adequate adhesion to polyurethane, for example:
*Mill Finish
Conversion Coating
Primer
Paint "overspray"
Organic Paints
• Acrylic
• Polyester
• Enamel
• Polyurethane
• *Fluoropolymer
Anodic Finishes
• Clear
• Integral Color
• Electrolytically deposited color
Anodic Finish Sealing Processes

• Boiling Water Seal
• *Nickel Acetate Sealing Additives
• Anti-smut Additives
*Mill finish, fluoropolymer paint finishes and nickel acetate sealing additives within the cavity have been shown to adversely affect
adhesion under some conditions and hence should be carefully evaluated.
Some designs employ a mechanical interlock and/or 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 be applied to the aluminum without affecting the shear strength of the system.
Powder coating and anodizing should not hurt the mechanical lock between the thermal barrier and the aluminum. However, before any
finishing operation is performed on the aluminum, the thermal barrier supplier should be consulted to ensure that the mechanical lock
between aluminum and thermal barrier will not be weakened.
Once the thermal barrier is inserted into the aluminum cavity, the complete section is ready to go through the rolling process. As the
aluminum and thermal barrier pass through the rolling machine the hammer on the aluminum cavity is forced into the thermal
barrier. The knurling on the aluminum is crimped into the thermal barrier creating the shear strength of the fenestration product.
4.3 Manufacturing Poured and Debridged Thermal Barriers
When applying polyurethane thermal barrier products, it is important to follow all of the manufacturers’ recommendations. For this
document, the manufacturing has been sub-divided into three separate and distinct phases:
1. Processing.
2. In-plant Handling and Fabrication.
3. Transportation and Installation of the Finished Product
The following sections will summarize generally acceptable procedures currently in use.
4.3.1 Material Processing
General processing parameters for polyurethane thermal barrier systems are contained in the following sections. Applicators should
follow the AAMA QAG-1 document for processing and record maintenance and all of the suppliers quality control guidelines.
FIGURE 14: Taped Extrusions Before Pouring (When required)
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 15: Pouring of Thermal Barrier
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
Debridging time is largely dependent upon the chemical characteristics of the material as provided by the supplier. Debridging time may
range from 3 minutes to 24 hours for safe debridging after pouring. Proper debridging technique is largely dependent upon the following
factors:
1. Poured extrusion temperature prior to debridging.
2. Aluminum mass vs. cavity size and location.

3. Cure time is affected by curing conditions, such as metal temperatures, plant conditions; and should be in accordance with
the supplier's recommendations.
4. The hardness of the thermal barrier material in the cavity should not be less than a durometer reading of 65 Shore D
recommended by the supplier. It is important to maintain dimensional stability during and after debridging. Stability is affected
by the plastic flow characteristics of the fill material. Extrusion "kick back" at the saw is another very real danger of debridging
material that is too soft.
NOTE 1: Hardness must be measured on a smooth cut surface.
5. Centering of the debridging cut should be between the retention lugs of the extrusion to provide maximum mechanical
interlocking of the profile.
6. Debridging should be done in such a manner as not to cut into or otherwise notch the thermal barrier material to provide
maximum mechanical strength to the profile while removing all of the aluminum bridge to maximize thermal performance.
7. The width of the debridging cut should range between 75% and 100% of the gap between the mechanical interlocks.
4.3.5 Handling, Care and Maintenance
Because of the unique properties of thermal barrier materials and the different handling requirements in the industry, this section will be
divided into three separate areas: Handling in the Plant, Handling During Storage, and Handling During Packing and Shipping. As in
any industry, certain common practices apply; the following statements could be used as a common guideline in all three categories:
1. The thermal barrier material needs time to develop its proper physical properties. This time period may vary depending on
specific formulations.
2. After this period, the filled and debridged extrusions should be handled per the suppliers recommendations.
4.3.5.1 Handling in the Plant
This section is designed for the manufacturer who keeps filling, debridging, and fabrication operations in-house. The filled extrusions
should not be abused after debridging. The appropriate debridging time will be supplied by the thermal barrier resin supplier. The
extrusions should be stacked in such a manner as to protect their dimensional stability during cure. The extrusions should be fabricated
only after recommended physical properties of the thermal barrier are reached.
4.3.5.2 Handling During Storage
This section can be used by both extruders and fabricators. Though the reasons for storage may vary, it is important to ensure quality
parts are available when needed, thus the following guidelines should be observed:
Care must be taken when extrusions are going to be stored in inventory. Extrusions need to be protected from damage to the finish and
distortion. Extrusions should be stored in symmetrical, banded bundles. Care must be exercised 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.
4.3.5.3 Handling During Packing and Shipping
In addition to the concerns of the previous two sections, there are conditions specifically related to shipping: heat, cold, shock, and
vibration are major considerations. Because of these factors, it is important to keep the extrusions in symmetrical bundles, with proper
band tension and paper interleaf to protect surfaces to ensure dimensional stability. In addition, the bundles should be placed on the
truck in such a way as to avoid excessive weight on the extrusions. Due to transporting across different geographical/climatic regions,
great temperature fluctuations are likely to occur. Extreme cold or heat may affect shock resistance and dimensional stability of the
extrusions.
After removing the extrusions from the vehicle at the destination, a stabilization period should be observed to bring the extrusions to
room temperature. Once room temperature has been reached, follow the guidelines in the previous two sections, Handling in the Plant
and Handling During Storage.
4.4 Installation of Poured and Debridged Thermal Barriers
4.4.1 Fabrication
Generally, the fabrication operations which are performed on thermal barrier sections are the same as those which are performed on
conventional, non-thermally improved sections. These processes consist of punching, drilling, 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 becomes necessary to
perform one or more of these fabrication operations in the cavity area, the following issues should be addressed where appropriate:
1. Provide sufficient clearance for the tooling (punch head, drill bit, milling head, etc.) to perform the desired operation without
marring or distorting the surrounding section.
2. Provide direct support on the back or underside of the section behind the thermal barrier cavity so that abnormal deflections
or stress concentrations do not occur, especially during punching and shearing operations.
3. Provide sufficient provision in the tooling design for chip and slug removal. Thermal barrier materials can quickly plug
fabrication tooling if allowances are not made for waste material removal.
4. Make provisions to prevent saw kick-back when cutting thermal barrier material along the length of the cavity as in end
notching.
5. Adjust the speed of operation, particularly punching, speed should be adjusted so as to minimize impact loading stresses.
With the cautions listed above fabrication of thermal barrier extrusions is not appreciably different than the fabrication of non-thermally
improved sections if the designer takes into account the properties of the thermal barrier materials as well as the properties of the
aluminum extrusions. In most cases common sense design and a knowledge of fabrication tooling and operations are sufficient. The
only real exception to this statement is in the curving or bending of thermally improved extrusions.
Because of the unique distribution of stresses and the possibility of excessive distortion, curving of thermally improved shapes should be
approached with caution by the designer. Stress concentrations and distributions can vary 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 cavity, the
specific formulation 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 or pouring after curving may be required for curved applications.
4.4.2 Job Site Storage/Handling
Many problems that can occur with thermal barrier sections at the job site can be eliminated by proper storage and handling during
installation. Whether stock length material or fabricated and partially assembled framing, the sections must not be abused. In no instance
should the material be dropped onto a hard surface or subjected to sudden impact loads. If long lengths of material are handled either
singly or in bundles, care should be taken to prevent excessive bending of the framing. More than a single load bearing point may be
required when using slings or cables when shipping. Care must be exercised to prevent excessive distortions of the framing in bundles
due to the use of "chocker slings" or other handling devices. Assembled frames should be unloaded and stored so as to prevent racking
or twisting. The stacking of material should be properly blocked and piles held to a limited height to avoid the application of excessive
weight to the material. Material which is received banded should be stored in this manner until actual installation is begun. All framing
products should be stored in an area free from traffic and other construction activities and out of direct exposure to the sun and other
elements.
Care must be exercised when anchoring the framing to the surrounding structure. Because of possibly high impact loading, power
actuated fastener guns should not be used to anchor thermal barrier extrusions especially in the cavity area. Proper shimming of anchors
will prevent excessive distortion of the framing as well as reduce the bending stresses in the fastener. Whenever possible fasteners,
particularly perimeter anchors, should be located no closer than 75 mm (3 in) to the cut ends of the framing.
The use of excessive amounts of some solvents or cleansing agents to clean the thermal barrier sections prior to or during glazing may
cause deterioration of the material. The installation contractor should check with the manufacturer of the framing for recommendations
for cleaning thermal barrier sections. The compatibility of sealants with thermal barrier compounds is another matter which should be
checked prior to application with either the framing manufacturer or the sealant supplier. As in the case of fabrication of thermal barrier
framing, the use of common sense and strict adherence to the guidelines furnished by the framing manufacturer will eliminate most
installation problems before they can occur.
4.5 Manufacturing of Mechanically Locking Preformed Thermal Barriers
When inserting mechanically locking preformed thermal barriers into aluminum extrusions, one should follow the recommendations on
the insertion equipment manufacturer as well as the supplier of the thermal barrier. The manufacturing of mechanically locked
preformed thermal barriers can be separated into the following subjects:
1. Knurling
2. Assembly
3. Crimping
The following sections will summarize generally acceptable procedures currently in use.
UNKNURLED KNURLED
FIGURE 16: Unknurled and Knurled Profiles
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 16)
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 17: 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 (two 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.

FIGURE 18 :Close-Up Picture Of Crimped Thermal Barrier Section
4.5.3 Crimping
1. Crimping – the squeezing of the sidewalls of the aluminum cavity to force the knurling on the inside walls of the aluminum
cavity to penetrate and lock the aluminum and the thermal barrier into one assemble section.
2. During crimping, one needs to be sure that the force crimping the aluminum into the thermal barrier is even on both sides of
the aluminum composite. The crimping machine will take care of this if properly adjusted.
3. One also needs to be sure that the crimping wheels are crimping the aluminum at the correct locations and squeezing the
aluminum hammer into the thermal barrier.
FIGURE 19: Picture of Rolling 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
The Mechanically Locked Preformed Thermal Barriers should be handled just as the individual aluminum extrusions to prevent damage
during handling. The mechanically locked thermal barrier has no special guidelines that need to be followed because of the insertion of
the thermal barrier.
4.5.4.2 Handling During Storage
The thermal barrier extrusions should be stored and handled to prevent damage to the finish on the aluminum extrusions. One wants to
make sure that no cosmetic damage occurs to the extrusions so that they can be used in the field. Care must be taken when extrusions are
going to be stored in inventory. Extrusions need to be protected from damage to the finish and distortion. Extrusions should be stored in
symmetrical, banded bundles. Care must be exercised 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.
4.6 Installation of Mechanically Locked Preformed Thermal Barriers
4.6.1 Fabrication
Generally, the fabrication operations performed on thermal barrier sections are the same as those performed on conventional, non-
thermally improved sections. These processes consist of punching, drilling, 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. If it becomes necessary to perform one or more of
these fabrication operations on the thermal barrier, the following issues should be addressed where appropriate:
1. Provide sufficient clearance for the tooling (punch head, drill bit, milling head, etc.) to perform the desired operation without
marring or distorting the surrounding section.
2. Provide direct support on the back or underside of the section behind the thermal barrier so that abnormal deflections or
stress concentrations do not occur, especially during punching and shearing operations.
3. Provide sufficient provision in the tooling design for chip and slug removal. Thermal barrier materials can quickly plug
fabrication tooling if allowances are not made for waste material removal.
4. Adjust the speed of operation, particularly punching, speed should be adjusted so as to minimize impact loading stresses.
With the cautions listed above fabrication of thermal barrier extrusions is not appreciably different than the fabrication of non-thermally
improved sections if the designer takes into account the properties of the thermal barrier materials as well as the properties of the
aluminum extrusions. In most cases common sense design and a knowledge of fabrication tooling and operations are sufficient. The
only real exception to this statement is in the curving or bending of thermally improved extrusions.
Because of the unique distribution of stresses and the possibility of excessive distortion, curving of thermally improved shapes should be
approached with caution by the designer. Stress concentrations and distributions can vary 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.
4.6.2 Job Site Storage and Handling
Proper handling of the thermal barriers sections should be followed as in the sections for poured and debridged thermal barriers Job Site
Storage/Handling. Stock length material whether it be just aluminum extrusions or assembled sections with the thermal barrier should
not be abused. In no instance should the material be dropped onto a hard surface or subjected to sudden impact loads. If long lengths of
material are handled either singly or in bundles, care should be taken to prevent excessive bending of the framing. More than a single
load bearing point may be required when using slings or cables when shipping. Care must be exercised to prevent excessive distortions
of the framing in bundles due to the use of "chocker slings" or other handling devices. Assembled frames should be unloaded and stored
so as to prevent racking or twisting. The stacking of material should be properly blocked and piles held to a limited height to avoid the
application of excessive weight to the material. Material that is received banded should be stored in this manner until actual installation
is begun. All framing products should be stored in an area free from traffic and other construction activities and out of direct exposure to
the sun and other elements.
Care must be exercised when anchoring the framing to the surrounding structure. Because of possibly high impact loading, power
actuated fastener guns should not be used to anchor thermal barrier extrusions especially in the cavity area. Proper shimming of anchors
will prevent excessive distortion of the framing as well as reduce the bending stresses in the fastener. Whenever possible fasteners,
particularly perimeter anchors, should be located no closer than 75 mm (3 in) to the cut ends of the framing.
The use of excessive amounts of some solvents or cleansing agents to clean the thermal barrier sections prior to or during glazing may
cause deterioration of the material. The installation contractor should check with the manufacturer of the framing for recommendations
for cleaning thermal barrier sections. The compatibility of sealants with thermal barrier compounds is another matter which should be
checked prior to application with either the framing manufacturer or the sealant supplier. As in the case of fabrication of thermal barrier
framing, the use of common sense and strict adherence to the guidelines furnished by the framing manufacturer will eliminate most
installation problems before they can occur.
5.0 ENVIRONMENTAL IMPACT

5.1 Effect of the Environment on the Design
The effect of environmental conditions on thermal barriers should be considered in design, application and incorporation into
fenestration products.
The environmental conditions to be most concerned about on exterior building products are exposure to ultraviolet light, water
immersion, high humidity, high temperature, low temperature, thermal cycling and cyclic bending. While each of these should be
considered on its own, it might be advisable to combine two or more when testing.
5.1.1 UV Exposure
All thermal barrier materials are resistant to structural degradation from UV exposure. Slight color change and/or surface crazing may
be experienced, but this will have little effect on the strength or impact resistance of the material. In cases where there will be full, direct,
exposure to the sun, it would be advisable to verify the performance with the thermal barrier supplier.
5.1.2 Water Immersion and Humidity Resistance
Thermal strut materials and polyurethane materials based on polyether polyols have adequate resistance to high humidity and the water
immersion that would result from ponding in the sill members. Long term adhesion in chemically bonded thermal barriers may be
affected with prolonged ponding of water on the thermal barrier.
5.1.3 Temperature Extremes
The extremes of temperature likely to be encountered in service will not degrade the thermal barrier material, but both high and low
temperatures will affect the properties while the material is at those temperatures.
In general, temperatures encountered in normal fenestration service applications, will not subject thermal barriers to structural
degradation. These extremes include both high and low temperature limits of the thermal barrier products.
5.1.4 Thermal Cycling
Alternate high and low temperatures may result in a reduction of adhesion or degradation, at interfaces between the poured and
debridged type of thermal barrier, and the 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.
In the past, thermal barrier extrusions were analyzed assuming adhesion or other interlocking forces between the aluminum and the
barrier material. This composite action results in a calculated moment of inertia that approaches the theoretical I value of the exterior
and interior aluminum portions of the extrusions adjusted for shear deformation of the thermal barrier material itself. If a reduction in
adhesion due to thermal cycling occurs during the AAMA 505 test, this shall be accounted for in calculations performed by a qualified
engineer to ensure the system will not pose a safety hazard.
The AAMA 505 thermal cycling test may reveal a condition called "shrink back" or “dry shrinkage”. This is a condition where the
thermal barrier shrinks back from the end causing a potential for air and water leakage. This cannot occur without a reduction in shear
strength. See Section 4.1.3 for an explanation of dry shrinkage.
5.1.5 Cyclic Bending
This refers to the repeated stresses that will occur when a composite section is subjected to positive and negative wind load reversals.
Experience and testing have shown that the thermal barrier materials currently being used are not adversely affected by this kind of
action. If a material with a much higher modulus or a very low ultimate elongation is being considered, cyclical flexure testing should be
performed.
5.1.6 Compatibility with Sealants
Materials used for thermal barriers have a good record of compatibility with all types of building sealants. For compatibility, neither the
sealant nor the thermal barrier shall be adversely affected by the other. Manufacturers can provide data on compatibility of materials
presently in use. Only new or untested materials need be tested for compatibility.
5.2 Effect of Thermal Barrier Materials on the Environment
Thermal barrier materials can impact on the environment in several ways, both in the manufacturing process and disposal. MSDS
and Product Data sheets for the products processed should be consulted and followed. Federal, State and local laws should be
reviewed to determine proper processing and disposal for the thermal barrier products being produced and handled.
6.0 TESTING
6.1 Thermal Barrier Material Properties
6.1.1 Scope
This section covers the preparation of standard-sized test samples and basic tests to determine the physical properties of thermal barrier
materials (solid or cellular). The thermal barrier component supplier typically provides this data. For pour and debridge quality checks at
point of application refer to AAMA QAG-1. For point of application quality checks for other thermal barrier systems, refer to the
thermal barrier component manufacturer.
6.1.2 Significance
The following tests can be of value in comparing physical properties of different materials. Material properties will vary widely
depending on the thermal barrier material used.
6.1.3 Description of Terms
The reader’s attention is drawn to the glossary in Appendix 7.6. It is essential that the terms used in the body of the document be clearly
understood if the document is to have full meaning.
6.1.4 Sampling of Poured Polyurethane
6.1.4.1 Test samples can be made in any suitable mold. The following two sizes are recommended: 305 mm x 150 mm x 6 mm (12 in x
6 in x 1/4 in), and 305 mm x 150 mm x 12 mm (12 in x 6 in x 1/2 in).
6.1.4.2 The procedures used to prepare the test sample relating to component ratios, temperature, mixing direction, mold temperature,
and curing conditions shall conform to the supplier's recommendations.
6.1.4.3 The test sample for reference purposes shall be allowed to age a minimum of 7 days before testing at 24°C ± 6°C (75°F ± 10°F).
6.1.5 Density
6.1.5.1 Procedure
Section density can be determined on any thickness of molded material. The minimum specimen length shall be 12 mm (1/2 in). Weigh
and measure the specimen to within ±1% of the value to be determined. Calculate the density as follows:
W
DENSITY = (kg/m3)
V
Where:
W = mass of specimen, kg
V = volume of specimen, m3
6.1.5.2 Report
The report shall include the following:
1. Density, to the nearest 1.6 kg/m3 (0.10 lbf/ft3).
2. Thickness, Height, Length and Weight.
6.1.6 Specific Gravity
Specific Gravity of regularly or irregularly shaped materials shall be determined according to ASTM D 792.
6.1.7 Tensile Properties
6.1.7.1 Determine the tensile strength and elongation according to ASTM D 638.
6.1.7.2 The following test parameters are recommended: The test specimen shall be a 19 mm wide by 6 mm thick (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 strength, elongation, any yield point, and %
strain at the yield point if present.
6.1.8 Hardness
Determine the hardness in accordance with ASTM D 2240 on the 6 mm (1/4 in) thick sample. Report the initial and a 5 second drift
value as determined on the top and the bottom surfaces. If the determination is to be made at subnormal temperatures, condition the
instrument at the same temperature. To prevent moisture from damaging the instrument, it is advisable to place the tester directly in a
desiccator after removing it from the cold box.
6.1.9 Compression Strength
Determine the compression strength in accordance with ASTM D 695. Cut the specimen from the 12 mm (1/2 in) sample, retaining the
molded surfaces.
6.1.10 Impact Strength
Determine the notched Izod impact properties in accordance with ASTM D 256 on the 12 mm (1/2 in) sample with the mold surface in
accordance with either method A or B.
6.1.11 Flexural Modulus
6.1.11.1 Determine flexural modulus, using the general procedure in ASTM D 790, Method I.
6.1.11.2 The following test parameters are recommended for thermal plastic materials:
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 6.4 mm
± 0.2 mm (0.250 in ± 0.01 in).
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. See Section 12.5.1 of ASTM D790.
NOTE 2: When calculating slope, use the steepest tangent as shown in Figure X1.1 of ASTM D790.
NOTE 3: 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 in ASTM
D790. Test data has shown that the faster rate provides a lower coefficient of variation than does the slower rate.
5. Condition a specimen at the test temperature for a minimum of 30 minutes before testing.
6.1.12 Thermal Conductivity
Determine the thermal transmission properties according to ASTM C 177 or C 518. Depending upon the size requirement of the tester,
special samples may need to be prepared. [The minimum recommended size is 305 mm x 305 mm (12 in x 12 in)]. The manufacturer
shall specify the mean temperature and Delta T.
6.1.13 Thermal Expansion
Determine the coefficient of thermal expansion according to ASTM D 696 using the 3 mm (1/4 in) thick sample. This test specifies a
temperature range of -66°C to 30°C (-86°F to 86°F); a broader temperature range may be tested, however the results may not be linear.
6.1.14 Heat Deflection Temperature
Determine the deflection temperature according to ASTM D648 applying 455 kPa (66 psi) on the 12 mm (1/2 in) specimen. The load
shall be applied to the surface not in contact with the mold.
6.2 Composite Performance
Thermally improved framing members typically consist of two aluminum sections joined together along their lengths by a thermally
insulating material. Poured and debridged and mechanically crimped in place thermal barriers are two commonly used designs to
improve the thermal efficiency of aluminum fenestration products. For poured and debridged designs, the insulating material is usually
polyurethane in composition and is poured in place over a thin metal bridge that temporarily connects the sections together. This bridge
is later removed by cutting or sawing after the thermal insulation has hardened sufficiently to permit handling of the extrusions. In its
final form the filled and debridged extrusion is in essence a composite structure (see Figures 1 and 2). Mechanically crimped thermal
barriers are assemblies which are comprised of thermal barrier struts and aluminum extrusions joined together mechanically. They are
also considered composite assemblies (see Figure 8). The kinds of tests required to determine the performance of thermal barrier
extrusions can be divided into two groups. The first group consists of structural properties such as bending strength, shear strength,
tensile strength and torsional strength. These are the kinds of properties normally required in engineering calculations. The second group
consists of properties such as impact strength, creep resistance, resistance to UV, humidity, ozone and retention of bond strength. While
not normally used in engineering calculations, this second group is none-the-less significant in determining the fabricating qualities of
extrusions and their long term performance in the environment.
Successful extrusion design requires knowledge of the basic structural properties of the thermal barrier composite. Moment of inertia
(second area moment) is important because it is a measure of stiffness and, hence, of the deflection under load of the composite. In
particular it is desirable to know if the connection between the semi-sections of the extrusion can be characterized as slip-resistant (i.e.,
little or no slipping between sections) and stiff (i.e., very little distortion due to shear force). If it is a slip-resistant and stiff connection,
then the effective moment of inertia will be higher than if the connection is not and a more cost-effective design can be achieved.
In many window and door designs much of the load is carried in shear in members designed to resist bending. Thus, shear strength of
the thermal barrier composite is a significant consideration.
Tensile loads on the thermal barrier material also occur frequently, especially as a consequence of negative wind pressure. Torsional
loads are placed on the thermal barrier material either as a direct function of design considerations or as a result of gasket pressures in
dry glazing systems.
The reader may refer to Appendix 7.5 for a method to calculate design values for effective moment of inertia (I'e), effective section
modulus (Se) and core shear for a thermal barrier composite. The beam span, section properties of each aluminum component, load type
(uniform, concentrated, triangular or trapezoidal), cavity dimensions and the shear modulus of the thermal barrier are needed for input.
Thermal barrier properties may be temperature dependent. Thus the beam's design properties must be evaluated with a shear modulus
value corresponding to the highest appropriate temperature expected at the mid-depth of the thermal barrier. See Section 6.5 and note
that the average of the metal temperatures of the exterior and the interior sides of the window frame may be conservatively taken as the
average thermal barrier temperature.
A CD of the design method in Appendix 7.5 has been included with this TIR which contains a Windows compatible program of this
design method and a program User’s Guide. This makes the method practical for quick, simple and suitably accurate evaluation of
composite properties for many shapes and sizes of extrusions. The method is based on original research done by John A. Hartsock.
FIGURE 20: Profile with Thermal Barrier System
The AAMA Test Extrusions were developed to provide the AAMA Thermal Barrier Structural Systems Task Group with useful and
adaptable test samples at a minimal amount of cost, for promulgation of viable test procedures and parameters. The modified I-beam is
easily gripped in fixtures for structural tests. Webs and/or flanges can be removed by sawing, to change the moment of inertia and
location of the thermal barrier with respect to the neutral axis. They also provide a "standard" cavity for thermal barrier material
suppliers' evaluation of various polyurethane formulations "in place". The AAMA Test Extrusions are NOT representative of typical
thermal barrier window shapes, were NOT intended for verification of product performance, and should NOT be used as such.
Manufacturers' standard extrusion shapes and cavity configurations in general make the most appropriate samples for this type of
testing.
6.3 Comparative Testing
There are many reasons for testing products with thermal barriers. Testing can be performed to verify composite performance as
outlined above. Testing can also be used as a means of comparing various aspects of the design of thermal barrier products. If the
designer is interested in evaluating different thermal barrier materials, he may choose to perform a series of tests using a standard cavity
such as the AAMA test extrusion filled with different barrier materials under various testing conditions. This would be very useful in
ascertaining which thermal barrier compound or design best fits the design conditions.
Another type of comparison might be obtained by testing several prospective cavity designs utilizing the same thermal barrier
compound or design. This type of testing is very helpful in optimizing cavity design for the anticipated design service conditions.
Normally, the manufacturer does this type of testing during the initial development of a new product.
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. AMA 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 procedures given are those that were used to develop the test
data and background information presented in other sections of this TIR. (Refer to Sections 7.2, 7.3 and 7.4).
6.5 Temperature Concerns
Many factors affect the temperature of architectural metals. Ambient air temperatures tend to determine the lowest experienced metal
temperatures. However, the highest temperatures experienced by the metal may be significantly higher than the highest ambient air
temperatures. This phenomenon is primarily attributable to the absorption of radiant energy from the sun by exposed metal surfaces. The
amount of radiant energy absorbed is affected by the color of the metal surface, shading of the metal and the angle of incidence of the
sun's rays on the exposed surface. Dark surfaces that are unshaded and on the sunny side of the building will experience surface
temperatures much higher than ambient air temperatures. Conversely, metal that is light colored and shaded may reach surface
temperatures only slightly higher than ambient air temperatures. Since most thermal barrier systems are designed to glaze insulating
glass units, the inside metal surfaces will experience a considerably smaller temperature range than the exterior faces of the framing. In
addition, if the glass is coated with a reflective or Low-E coating, the inside metal is shaded as well as insulated from the sun's radiant
energy. Under these conditions, inside metal surface temperatures may vary little from ambient room temperature in occupied buildings.
In composite thermal barrier systems, the differential temperature between the interior and the exterior metal may cause the framing
members to deflect. For example, on a hot day, the exterior will tend to expand more than the interior creating an outward deflection.
Conversely, on a cold day, when the exterior metal is much colder than the interior metal the framing member will tend to deflect
inward. These deflections result in additional shear stresses in the thermal barrier that are similar to the shear stresses caused by wind
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 stresses during the design of a project. Refer to ASHRAE’s Handbook of
Fundamentals for Heating and Wind Design Conditions for various portions of the United States, Canada and other World Locations. It
is very unlikely that these temperature extremes will correspond with the maximum design wind loads; therefore when combining these
loads it is generally acceptable to apply a combined load reduction factor.
The flow of energy in a thermal barrier composite section must also be considered. This flow is greatly affected by the surface area to
mass ratio of both the interior and exterior exposed framing members. Therefore, even though an exposed exterior face may become
very hot from radiant energy in still air, if the mass is relatively low compared to the exterior surface area it will tend to cool very
rapidly convectively when the wind blows. This is particularly true of a material with high thermal conductivity such as aluminum. This
means that when a wind load is applied to the framing, the temperature of the external face will be much closer to ambient air
temperature than when there is no wind. The temperature on the interior surface is difficult to predict but it will sometimes reach a
temperature in excess of 11°C (20°F) above ambient depending on interior conditions such as drapes, blinds and recesses. This
moderates the effect of radiant energy on the temperature gradient through the framing. This effect should also be of prime concern to
the design professional when analyzing the appropriateness of a particular framing application.
6.5.1 Thermal Performance Factors
When choosing a particular framing system, the design professional should address the following minimum set of factors affecting
thermal performance:
1. What is the color of the framing?

2. Where is the glazing located with respect to the depth of the frame?
3. Where is the thermal barrier located with respect to the depth of the frame?
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)}
CHART 1: Temperature Concerns
4. Is the glazing material insulating

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 designer can delineate the appropriate thermal performance specifications.
6.5.2 Guidelines
The following guidelines were derived from the experiences of and the testing done by the members of AAMA, the National Research
Council of Canada, the American Society of Heating, Refrigeration and Air Conditioning Engineers and other sources involved in the
glazing industry and related fields. They should not be construed as absolutes but rather as guidelines to assist the design professional
who will make the ultimate specifications decision based on knowledge and experience.
6.5.3 Examples
The following examples indicate the method of determining the approximate surface temperatures for various geographical locations:
6.5.3.1 Example #1:
Location: Indianapolis, Indiana

Ambient outside air temperature (OAA): -32°C (-25°F) in the winter, 41°C (106°F) in the summer.
Building is glazed on all four sides and oriented with one axis north to south and the other axis east to west. The framing will be clear
anodized (Condition 6) with reflective insulating glass (Condition 1). Tempered air inside the building will be maintained at
approximately 21°C (70°F) both winter and summer (IAA).
From Chart 1, the inside surface temperatures (Condition 1) would be:
ISTS = IAA + (11°C) to IAA + (17°C) = (21°C + 11°C) to (21°C + 17°C) = 32°C to 38°C (90°F to 100°F) in summer.
ISTW = IAA – (11°C) to IAA – (6°C) = (21°C - 11°C) to (21°C - 6°C) = 10°C to 15°C (50°F to 60°F) in winter.
From Chart 1, the outside surface temperatures (Condition 6) would be:
OSTS = OAA + (17°C) to OAA + (22°C) = (41°C + 17°C) to (41°C + 22°C) = 58°C to 63°C (136°F to 146°F) in summer.
OSTW = Equal to OAA = -32°C (-25°F) in winter.
The inside thermal range (hottest summer inside surface temperature to coldest winter inside surface temperature) would be:
ISR = 38°C – 10°C = 28°C (50°F)
The outside thermal range (hottest summer outside surface temperature to coldest winter outside surface temperature) would be:
OSR = 63°C – (-32°C) = 95°C (171°F)
The thermal barrier temperatures (average of hottest inside and hottest outside surface temperatures) would be:
TBTS = (38°C + 63°C)/2 = (101°C)/2 = 50.5°C (123°F) in summer.
TBTW = [15°C + (-32°C)]/2 = (-17°C)/2 = -8.5°C (17.5°F) in winter.
The temperature range for the thermal barrier material would be:
TBR = 50.5°C to -8.5°C or a range of 59°C (105.5°F)
6.5.3.2 Example #2:
Location: Seattle, Washington

Ambient outside air temperature (OAA): -16°C (3°F) in the winter, 37°C (98°F) in the summer.
Building is glazed on the north and west sides and oriented with one axis northeast to southwest and the other axis northwest to
southeast. The framing will be light bronze anodized (Condition 7) with clear insulating glass (Condition 2). The glazed openings are
shaded under a 2 m (6 ft) overhang with coniferous ground shrubs. Tempered air inside the building will be maintained at approximately
18°C (65°F) in the winter and 24°C (75°F) in the summer (IAA).
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.
OSTS = OAA + (22°C) to OAA + (28°C) = (37°C + 22°C) to (37°C + 28°C) = 59°C to 65°C (138°F to 148°F) in summer.
OSTW = Equal to OAA = -16°C (3°F) in winter.
ISR = 46°C – (-10°C) = 56°C (100°F)
The outside thermal range (hottest summer outside surface temperature to coldest winter outside surface temperatures) would be:
OSR = 65°C – (-16°C) = 81°C (145°F)

TBTS = (46°C + 65°C)/2 = (116°C)/2 = 55.5°C (131.5°F) in summer.
TBTW = [12°C + (-16°C)]/2 = (-4°C)/2 = -2°C (29°F) in winter.

TBR = 55.5°C to -2°C or a range of 57.5°C (102.5°F)
6.5.3.3 Example #3:
Location: Phoenix, Arizona

Ambient outside air temperature (OAA): -9°C (16°F) in the winter, 48°C (119°F) in the summer.
Building is glazed on all four sides and oriented with one axis north to south and the other axis east to west. The framing will be black
anodized (Condition 8) with clear monolithic glass (Condition 4). Tempered air inside the building will be maintained at approximately
24°C (75°F) in the winter and 18°C (65°F) in the summer (IAA).
NOTE 4: Because the southern exposure is next to a highly reflective surface (the swimming pool), the designer may wish to increase
the outside summer surface temperature. The winter outside surface temperature would be unaffected because at -9°C (16°F) the pool
would either be drained or covered. A summer outside surface temperature of 88°C (190°F) will be used for this example.
ISTW = IAA – (11°C) to IAA – (6°C) = (24°C - 11°C) to (24°C - 6°C) = 13°C to 18°C (55°F to 65°F) in winter.
OSTS = OAA + (28°C) to OAA + (33°C) = (48°C + 28°C) to (48°C + 33°C) = 76°C to 81°C (169°F to 179°F) in 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.
ISR = 62°C - 13°C = 49°C (90°F)
The outside thermal range (hottest summer outside surface temperature to coldest winter outside surface temperature) would be:
OSR = 81°C – (-9°C) = 90°C (163°F)
Since the designer has decided to use an altered outside summer surface temperature for this project, his specification would produce
an outside surface temperature range of:
OSRP = 88°C – (-9°C) = 97°C (174°F)
TBTS = (62°C + 81°C)/2 = (143°C)/2 = 71.5°C (162°F) in summer.
Since the designer has decided to use an altered outside summer surface temperature for this project, his specification would produce a
thermal barrier temperature of:
TBTSP = (62°C + 88°C)/2 = (150°C)/2 = 75°C (167.5°F) in summer.
TBTW = [18°C + (-9°C)]/2 = (9°C)/2 = 4.5°C (40.5°F) in winter.
TBR = 71.5°C to 4.5°C or a range of 67°C (121.5°F).

Since the designer has decided to use an altered outside summer surface temperature for this project, his specification would produce a
thermal barrier temperature range of:
TBR = 75°C to 4.5°C or a range of 70.5°C (127°F).
The examples above indicate how the factors mentioned earlier can affect the required performance of the thermally broken framing
system. It is up to the person writing the thermal specifications for the installation to clearly outline the applicable factors and
intelligently interpret the manner in which these factors impact thermal specifications. Only in this manner can poorly written,
incomplete or unrealistic thermal specifications be avoided.
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:
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 1: Results of Thermal Analysis
6.6 Testing Temperatures
The temperatures, temperature ranges and thermal guidelines given above are very useful to those selecting or specifying thermally
broken framing systems. They can also be of considerable use to manufacturers of framing systems and suppliers of system components.
Suggested test methods for determining the bending, tensile, shear and torsional properties of thermally broken sections are given in the
Appendix of this TIR. Since the properties being tested may vary widely with temperature, it is paramount that appropriate testing
temperatures be determined prior to testing.
Test data should be obtained at enough different temperature settings to adequately represent the field conditions under which the design
will perform. A minimum number of thermal test points would represent room temperature, 24°C (75°F), and the highest temperature
which the thermal barrier material would experience under field conditions as outlined in the guidelines given above. A complete
temperature profile would include test data at -18°C (0°F), room temperature, 24°C (75°F), 60°C (140°F) and 71°C (160°F) as
measured at the thermal barrier. The first temperature range would be appropriate during product testing while the second range would
be more useful during product development.
The selection of temperature criteria for testing purposes should be done with caution and due consideration of the cost of testing. Care
should be exercised that the test results are derived from testing done under conditions as close to anticipated field conditions as
possible. If in doubt, use the guidelines offered above or consult qualified engineering personnel. It is usually desirable to evaluate the
performance of several composite designs and materials during product development. Therefore a wider range of test temperatures and
the concurrent increased cost of testing is justified.
However, once the design and materials have been finalized, only those test temperatures representing the extremes of product thermal
exposure are justifiable from a cost of testing standpoint. If the manufacturer has performed this minimum amount of testing and
provides this data to the product user or specifier, then it is doubtful that job testing for thermal performance would serve any useful
purpose. Only in situations where anticipated field conditions exceed the temperature extremes tested would additional testing be
appropriate.
6.7 Safety Factor
The average values from testing are divided by an appropriate safety factor to determine the allowable values used for structural
design of the composite member. The following recommendations and discussion are based on a study of the safety factor for
longitudinal shear strength. This study considered a procedure in Section 8.3 of the Aluminum Association’s "Specifications for
Aluminum Structures; Allowable Stress Design" (7th edition) and test data for six sets of 20 specimens each. Each set used a
different combination of cavity finish and polyurethane barrier. A recommended safety factor of 2.5 is given in AAMA 505.
The value of 2.5 for the safety factor, for longitudinal shear strength, has been found to be appropriate for products with a coefficient
of variation (Cv) not exceeding 11.9%. If a product (with a particular combination of cavity surface finish, specific thermal barrier
type, etc.) has a Cv greater than 11.9%, then the required safety factor, but not less than 2.5, is to be computed using Section 8.3.2 of
the Aluminum Association’s specifications.
The value of 11.9% is based in part on review of six sets of data (for variations and trends), but more generally on Section 8.3.1 of
the Aluminum Association’s specifications. This value is based on the use of a 1.5 load factor to calculate a value of 0.6 (= 1.5 / 2.5)
for the under-capacity factor (φ), and a statistical coefficient K of 3.37 for 18 specimens. The nominal value of strength Sn is
considered to be the average Xm . The value 0.6 is then substituted in Equation 8.3.1-1, written in terms of Cv and φ:
X a = X m – K Sx = φ S n = φ X m
Φ Xm / Xm = (Xm – K Sx) / Xm = 1- K Cv = φ = 0.6
Cv = (1-0.6) / 3.37 = 0.1187
Both sides of Eq. 8.3.1-1 have been divided by Xm so as to get the equation in terms of φ and Cv. The calculated value is of Cv is
11.87%.
Some interpretation is needed to use Section 8.3.2 and engineers may differ on exactly what values to use for the formula in that
section of the Aluminum Association specifications. If one uses β0 equal to 3.5 (connections), 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 safety factor of 2.5002. Thus this approach supports the use
of 11.9% for Cv since 0.1196 is greater than 11.9%. 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
FIGURE 21a: AAMA Die Profile Drawing For Poured & Debridged And Mechanically Crimped In Place Test Cavities

FIGURE 21b: AAMA Die Profile Drawing for Poured & Debridged
7.2 Flexural Test
7.2.1 Scope
7.2.1.1 This test method shall be used to determine the effective moment of inertia (effective second area moment) of
aluminum/elastomeric composites, and complex sections, in lieu of calculations. This test method shall also be used to determine
“effective” shear modulus as defined in Section 7.5.3.1.
7.2.1.2 In general, the theoretical moment of inertia (I) of a composite (assuming the aluminum sections are "fixed" in relation to each
other; i.e., no shear deformation is included) will be greater than the effective moment of inertia (Iet) determined by this procedure. This
test is designed as a useful method of determining apparent effective moment of inertia.
7.2.1.3 This test procedure may be used either to evaluate the performance of a specific thermal barrier material or to evaluate the
performance of a particular thermal barrier material and extruded aluminum shape as a composite, or a combination of the above. An
aluminum composite section is defined as:
COMPOSITE SECTION - Any combination of aluminum and one or more non-metallic materials such as elastomers, polyurethane,
plastics, vinyl, etc. which are used as a thermal barrier joining the aluminum sections. The components of this structure act together in
such a manner that their joint structural performance is greater than the performance of the sum of the individual components acting
separately.
7.2.1.4 This test procedure is subject to several limitations:
1. The effective moment of inertia is only valid within the elastic range of the composite section. The effective moment of
inertia is, in general, exactly correct only for the span and type of loading used in the test. It is approximate for other loading
types (e.g., distributed vs. concentrated) and span values. Under certain physical circumstances the thermal barrier material
may reach its yield or even ultimate strength before the aluminum. Factors such as temperature, cavity location and thermal
barrier material selected will all affect the results of the procedure. The section being tested may behave in the field consistent
with a smaller moment of inertia than the effective value calculated in the lab. Care must be exercised that the test results are
derived from testing done under conditions as close to field conditions as possible. If in doubt, consult qualified engineering
personnel.
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 encountered under actual field conditions will normally result in the smallest moment of inertia of the
composite. For this reason, the effective moment of inertia derived in the lab shall be calculated from test results that closely
simulate the maximum anticipated field temperatures of the thermal barrier material. While temperatures on the exterior
surfaces of aluminum building products can reach 82C (180F) for dark colors, maximum wind loads will not occur when
these high temperatures are experienced because air movement will cool the aluminum to near ambient levels. It is therefore
reasonable to assume that the maximum wind loads will not occur when the exterior surface of the thermal barrier sections is
over 49C (120F).
If this method is used to find the effective shear modulus (Gc) of the thermal barrier, or to compare the test value of effective moment of
inertia (Iet) to a theoretical value with shear effects (Ie or I'e; Section 7.5), then measurements of actual widths, thicknesses and depth of
the composite are needed. The actual measurements would be used to determine input for the procedure in Section 7.5.

7.2.1.5 The test method subjects the composite specimen to a small deflection from a concentrated load at the center of the span. The
specimen is loaded as a simply supported beam. Care must be taken to avoid eccentric loading that could result in rotation. It is assumed
for the purposes of this test method that stresses will remain within the elastic range of the materials, the restraints provided at the
supports simulate a simply supported end condition and the modulus of elasticity of the composite section remains approximately equal
to that of aluminum 68.9 x 106 kPa (10 x 106 psi).
7.2.1.6 By accurately measuring the concentrated load applied and the resulting center deflection, the effective moment of inertia for the
composite section can be determined by using the standard deflection formula for a simply supported beam with a concentrated load at
the center. Solving for the effective moment of inertia:
PL3
Iet =
48E∆
Where:
Iet is the effective moment of inertia for the composite section, based on testing.
P is the applied concentrated load at midspan.
L is the length of the span between reaction points.
∆ is the deflection of the center of the span due to the applied load.
E is the modulus of elasticity for aluminum.
7.2.2 Procedure
7.2.2.1 The test specimen shall be supported at the reaction points by a knife edge or a round rod. Free rotation of the specimen in the
plane of the loading shall be permitted.
7.2.2.2 Loads shall be applied so as not to permanently distort the specimen or cause it to pass the elastic yield point. This may be
accomplished by restricting the span of the specimen to a maximum (Lm) and limiting the load:
12 Ehn Rt0.5
L≤
175 Fty
4 FtyIRt
P≤
Lhn
These formulae assume the composite remains within the elastic limit of the aluminum and that the maximum deflection will not exceed
L/175 (a standard architectural aluminum deflection limit). Specimen lengths shorter than L when subjected to load P will result in
deflections less than L/175.
Where:
L is the distance between the support points in millimeters (inches).
E is the modulus of elasticity for aluminum. It equals 68.9 x 106 kPa (10 x 106 psi).
hn is the distance from the center of gravity of the section being tested to the farther of its extreme fibers. Thus n = 1 or 2, as shown in
Figure 31 in Section 7.5.8. An initial estimate of one-half the composite's depth is acceptable if more exact section property information
is not available. However, if this estimate is used it is suggested the test be run at a series of gradually increasing loads and the results
plotted to ensure the test is being conducted within the elastic range of the composite.
Fty is the specified minimum yield stress. The value for 6063-T5, a commonly used grade of aluminum, is 110,316 kPa (16,000 psi).
NOTE 5: 1 kPa = 0.001 N/mm2.
I is the calculated moment of inertia of the unpoured test specimen in mm4 (in4). This is an upper bound on the effective moment of
inertia (Ie or I'e in Section 7.5) of the composite.
P is the maximum permissible load, which meets deflection and stress limits, in Newtons (pounds)
Rt is a reduction factor to account for stress and deflection increases, due to shear deformation of the thermal barrier (core). A value of
0.9 is suggested for many cross-sections, not for final design but solely for this test procedure.
7.2.2.3 Testing equipment shall be calibrated in accordance with ASTM test method E 529, Paragraph 9. If a testing machine is used, the
speed of loading shall be 5 mm (0.200 in) per minute ±50%.
7.2.2.4 Deflection shall be measured and recorded to the nearest 0.03 mm (0.001 in) absolute. Deflection shall be measured at the center
of the span and at each end support. The sum of the deflections at the supports shall be averaged and subtracted from the center
deflection to get an overall net deflection of the beam. Deformation shall be determined both after the completion of load application
and after the load has been maintained for five minutes. Care shall be taken to ensure that the deflection does not exceed the ratio L/175.
7.2.2.5 Permanent deformation of the specimen shall not exceed 0.2% of the clear span between supports. If this value is exceeded 15
minutes after the load has been removed, the test results shall be discarded, the failure recorded and the test rerun on a new specimen at
a reduced load.
7.2.3 Test Cycles
7.2.3.1 The load P may be increased from zero to maximum P in any convenient increments but a minimum of 5 data points shall be
obtained at zero, 1/4 P, 1/2 P, 3/4 P and maximum P. After preliminary establishment of an average effective moment of inertia it may
be desirable to test a limited number of specimens at a greater number of load levels to increase the statistical significance of the results.
Further testing would be indicated if one or more of the test results deviates from the average by greater than ± 5%.
7.2.3.2 Test data shall be obtained at ambient conditions that adequately represent the field conditions under which the design will
perform. Temperatures of the test room, thermal barrier material and heated section of the aluminum extrusion shall be recorded if
applicable.
1. The test specimen may be most conveniently heated with an electric heat tape. The heat tape shall be applied to the
exterior face of the aluminum extrusion. Thermocouples shall be located under the heat tape, imbedded in the center of the
thermal barrier material and on the surface of the interior face of the aluminum extrusion (see Figure 22). The thermo-
couple on the exterior face shall be used to control the temperature at which the test is conducted. The thermocouple
imbedded in the thermal barrier material shall be the used to determine that stabilization has occurred before the test is
conducted. The thermocouple on the interior face will be used to determine the 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 22: Thermocouple Placement
2. Temperature readings shall be taken as outlined above. The load shall not be applied until three consecutive temperature
readings from the thermal barrier thermocouple agree within ± 1°C (± 2°F) of the desired temperature setting. The period of
temperature stabilization shall not be less than 5 minutes nor shall the time between consecutive readings be less than 1 minute.
Failure to allow the test specimen to stabilize at the equilibrium temperature as measured by the thermal barrier thermocouple
will result in non-reproducible results.
3. Ambient conditions during testing shall be maintained at 24°C ± 3°C (75°F ± 10°F) with minimal air flow across the
specimen.
7.2.4 Report
7.2.4.1 A report of test results should generally be in accordance with ASTM Standard Practice E 575.
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 23: Shear Test Fixture
FIGURE 24: Dual Cavity
7.3.1 Scope
This method describes procedures for determining the shear, tensile and eccentric loading strengths of thermal barrier materials.

7.3.2 Sample
A sufficient number of pieces of test extrusions shall be selected in such a manner as to be representative of the 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. For dual cavity,
test each cavity separately and record lowest shear value.
LOAD 'P'
TENSILE
TEST TEST
FIXTURE
LOAD 'P'
TEST
FIXTURE
FIGURE 25: Test Fixture

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 26: Eccentraic Load Test
FIGURE 27: Dual Cavity Eccentric Load Test
7.3.3 Test Conditions
Unless otherwise specified, tests shall be conducted at 24°C ± 3°C (75°F ± 5°F). Sections 6.5 and 6.6 provide guidance to the design
professional in determining the appropriate conditions for his/her project requirements.

7.3.4 Test Specimens
Ten specimens each 100 mm ± 1.0 mm (4.00 in ± 0.04 in) in length shall be cut with smooth, square cut edges from extrusions whose
dimensions, shape and composition represent the desired test extrusion.
7.3.5 Preparation of Specimens
The thermal barrier material to be tested in the extrusion shall be poured and debridged or inserted and crimped in accordance with the
supplier's recommendations. For polyurethane thermal barrier systems, special care shall be taken to ensure that the polyurethane is
mixed at the correct ratio, to complete uniformity and fully fills the cavity of the extrusion. In addition, debridging shall be properly
centered and done in such a manner as not to cut into or otherwise notch the thermal barrier material while completely removing the
metal bridge. Unless otherwise specified, the composite assemblies shall be allowed to cure a minimum of seven days according to the
supplier's recommendations. For crimped in place thermal barrier systems, care should be taken to properly knurl and crimp the
preformed thermal barrier in place.
7.3.6 Apparatus
A universal testing machine capable of exerting a force of up to 2250 N (10,000 lbs) at a crosshead speed of 5.0 mm/min (0.2 in/min)
shall be used.
For gripping the shear test specimens a test fixture designed for offset loading shall be required. The test fixture shall prevent rotation of
the specimen under load and shall provide clearance for downward travel of the loaded side. A bearing plate shall be placed on top of
the unsupported side of the test specimen.
For shear testing, the test fixture shown in Section 7.3, Figures 23 and 24 or its equivalent shall be used. It should be noted that this test
fixture is the same one used in the eccentric loading test except that the top plate has been rotated 180° to provide clearance for offset
loading. For gripping the tensile test specimens a slotted, self aligning test fixture shall be required. For tensile testing, the test fixture
shown in Section 7.3.2, Figure 25 or its equivalent shall be used. Figures 23, 24, 25 and 26 show the test specimens mounted in the
shear, tension and torsion fixtures respectively. In all cases, the applied loads shall be distributed as uniformly as possible along the
unsupported section so as not to distort or bend the aluminum. In some cases, the thermal barrier will be stronger than the aluminum and
distortion of the aluminum is unavoidable.
7.3.7 Procedure
7.3.7.1 Tests at Temperatures Below Room Temperature
The test specimen and test fixture shall be placed in a suitably equipped environmental test chamber mounted on the universal testing
machine. A thermocouple shall be inserted into a hole 1.5 mm (0.062 in) in diameter and 5 mm (0.2 in) deep drilled into the midpoint of
the thermal barrier compound along its centerline at a point 75 mm (3 in) from the end of the specimen. When the temperature indicated
by the thermocouple has stabilized at the desired value, the load shall be applied at a strain rate of 5 mm/min (0.2 in/min) until failure
occurs. For torsional testing, the face of the compression rod shall be approximately centered on the fin of the extrusion closest to the
thermal barrier material. Record test results as the moment developed from the applied load times the distance of the applied load to the
centerline of the thermal barrier. For shear and tensile testing, record the peak load and the mode of failure (whether cohesive within the
thermal barrier material or whether the thermal barrier material pulled free from the extrusion cavity projections) or, as in the case of
shear testing, slipped parallel to the direction of travel.
7.3.7.2 Tests at Room Temperature
The same procedure as in Section 7.3.7.1 shall be used except that the environmental test chamber and thermocouple temperature probes
are not required. Room or ambient conditions shall be maintained at 24°C ± 3°C (75°F ± 5°F).
7.3.7.3 Tests at Temperatures Above Room Temperature
The same procedure as in Section 7.3.7.1 shall be used except that the environmental test chamber shall be replaced by an electrical heat
tape. The heat tape shall be applied to the exterior face of the aluminum extrusion. Thermocouples shall be located under the heat tape,
imbedded in the center of the thermal barrier material and on the surface of the interior face of the aluminum extrusion. The
thermocouple under the heat tape shall be in direct contact with the metal surface but shall be shielded from direct contact with the heat
tape by means of an insulating shim (see Figure 22). The temperature measured by the exterior face thermocouple shall be the
controlling test temperature. All three thermocouple readings shall be recorded in the test report.
Temperature readings shall be taken as outlined above. The load shall not be applied until three consecutive temperature readings from
the thermal barrier thermocouple agree within ± 1°C (± 2°F) of the desired temperature setting. The period of temperature stabilization
shall not be less than 5 minutes nor shall the time between consecutive readings be less than 1 minute. Failure to allow the test specimen
to stabilize at the equilibrium temperature as measured by the thermal barrier thermocouple will result in non-reproducible results.
7.3.8 Report
7.3.8.1 A report of test results should generally be in accordance with ASTM Standard Practice E 575.
7.3.8.2 As a minimum, the information included in attachment B shall be included in the report format. (Reference Section 8.2).
7.4 System Performance Requirements
Composite thermal barrier systems must perform not only thermally but also equally well as a structural component of the total building
system. For structural performance, refer to AAMA 505. In addition, they must perform satisfactorily in resisting air and water
infiltration. The system performance limits should be set by the architect or engineer responsible for the project. AAMA has developed a
series of minimum performance requirements and test methods to aid the design professional. A discussion of these tests and standards
is given in the following paragraphs. More complete information is available in the documents which are listed in Section 9.0
References.
7.4.1 Structural
(AAMA Curtain Wall Guide Specifications, par 1.07.B)

This test is performed in accordance with ASTM E330. Design limits for deflection at design load are held to 1/175 of the clear span for
curtain wall, storefront and HC and AW windows. At a test pressure of 1.5 times the design load, permanent deformation is limited to
0.2% of the clear span for main curtain wall, storefront, entrance framing and AW windows and doors, 0.3% for HC and C windows and
doors and 0.4% for R and LC windows and doors. Glass breakage, permanent damage to fasteners, anchors, hardware or actuating
mechanisms is not permitted.
7.4.2 Water
(AAMA Curtain Wall Guide Specifications, par 1.07.D)

This test is performed in accordance with ASTM E331. The appearance of uncontrolled water other than condensation on the indoor
face of the wall is not allowed. Static test pressure is usually 20% of the architect specified design pressure for curtain wall, storefront,
entrance framing and AW windows and 15% of the design pressure for R, LC, C and HC window, door and panel members. For curtain
walls, a dynamic test for water penetration is also frequently run at the same test pressures. Penetration of a small amount of water is
considered permissible, provided it is contained and drained back outside (or "controlled"), with no damage to the wall or adjacent
structures.
7.4.3 Air
(AAMA Curtain Wall Guide Specifications, par 1.07.C)

This test is performed in accordance with ASTM E283. The test pressure is specified by the architect with 1.57 psf usually being the
minimum test pressure. Air infiltration is limited to 0.3 L/s•m2 (0.06 cfm/ft2) per square foot of projected wall area for fixed storefront
and curtain wall glazing. 101/I.S. 2/NAFSprovides air leakage limits for all other fenestration types. Air infiltration is measured after a
tare reading for air leakage of other building components or the test chamber is deducted.
7.4.4 Thermal
(AAMA Curtain Wall Guide Specifications, par 1.07.E)

Thermal performance standards are especially important for thermally improved framing systems. Thermally broken systems offer a
considerable reduction in the formation of harmful condensation on the interior of the glazing. A considerable reduction in heat flow or
thermal transmittance is also a benefit provided by thermally broken systems. Both of these performance improvements may be
relatively measured by AAMA 1503.
7.4.4.1 Condensation Resistance Factor (AAMA 1503)
The Condensation Resistance Factor (CRF) is a rating number, obtained under standard test conditions, which allows comparison within
reasonable accuracy, of the condensation performance of windows, doors or glazed wall sections. CRF ratings are derived at standard
test conditions of -18°C (0°F) on the cold side of the specimen, 21°C (70°F) on the warm side and a uniform air flow against the cold
side of the specimen of 7m/s (15 MPH). Temperatures on the surface of the specimen are used to compute a CRF rating.
Since CRF is determined for a pre-specified configuration under controlled laboratory conditions, caution must be exercised in using
CRF to predict field performance against the formation of condensation.
7.4.4.2 U-factor (AAMA 1503 and AAMA 507)
The Thermal Transmittance (U-factor) is the time rate of heat flow, per unit area, under steady state conditions, through a body for a unit
temperature difference of air on either side of the body. The AAMA 1503 test method used to determine a U-factor is a modification of
ASTM C236. The test chamber conditions are the same as for the CRF procedure given above. The calculation of U-factor is a function
of inside and outside surface coefficients as determined by measured specimen surface temperatures and affected by air flow. There are
many factors that can impact the actual U-factor of a glazing installation such as glass type and glass to frame ratios. These variables are
taken into account for U-factors determined in accordance with AAMA 507. In general it is up to the architect to determine how the job
conditions relate to test conditions, particularly test size versus installed framing size.
7.5 Structural Design Method for Composite Aluminum/Elastomer Beams
7.5.1 Overview of Sandwich Beams
Why do we need to treat thermal barrier beams differently than ordinary beams? This discussion addresses this question.
The key structural difference between an all-aluminum beam and a composite, thermal barrier beam is core (thermal barrier) shear
deformation. Most of the behavior of an all-aluminum beam can be modeled using the traditional Bernoulli-Euler equation (E I y′′ = M)
for flexure, while ignoring shear strain. However, introduction of a relatively soft material for a part of the web (thermal barrier or core)
results in a more complex behavior of the beam. Initially plane (flat) cross-sections of the beam do not remain so after loading, due to
significant effects from shear deformation of the core. Core shear strain entails rectangular blocks of the core, with length parallel to the
beam’s span, distorting into parallelograms.
Beam deflection and aluminum stress both increase, due to the presence of a core which is “soft” compared to aluminum. On the other
hand, the value of longitudinal shear flow (shear stress times core width) is less with a core than for an otherwise similar, all-aluminum
beam.
There is another way to think of thermal barrier beam behavior, besides the concept of altering an all-aluminum beam so that it becomes
more flexible and more highly stressed. One can consider the idea of joining two separate pieces of aluminum to create a beam which is
stiffer and stronger than the un-joined pieces. As an example, two identical aluminum bars are placed, one on top of the other, so as to
span between supports. (See Figure 28) A certain midspan load will cause the beam to sag 25 mm (1 in) (Case ‘a’). In this set-up, the two
bars are free to slide along each other so that the top of the lower bar is in compression and the bottom of the upper bar is in tension. Now
assume (Case ‘b’) that the two bars are “glued” together so that any strains in the contacting bar surfaces are forced to be identical. The
same load and span will now produce only 6 mm (1/4 in) deflection and half as much bending stress. These improvements come at a cost
however, since the “glue” must resist a longitudinal shear flow which is equal to the maximum shear flow that exists within each bar in
Case ‘a’.
The behavior of a thermal barrier beam is, in a sense, between Case ‘a’ and Case ‘b’. If the glue acquires a finite thickness and exhibits
significant shear deformation, then one has a model of a composite thermal barrier beam. The core’s shear stiffness engages the axial
stiffness of each face. In addition, the core forces both faces to deflect the same amount, and so the individual bending stiffness of each
face also assists in resisting the load.
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 28: Thermal Barrier Beam Behavior using Joint Beams
7.5.2 Introduction to Method
Section 7.5.1 describes a design method for predicting the stiffness (effective moment of “inertia” [second area moment]), effective
section modulus, and core shear for a simple span beam with a non-homogeneous cross-section, subject to midspan concentrated,
uniform, triangular or trapezoidal load. All load types are symmetrical about the midspan of the beam. The model is a “sandwich” beam
consisting of relatively stiff faces (e.g., aluminum) continuously joined to a much softer core material (e.g., an elastomer such as
polyurethane, or a material such as glass-fiber reinforced nylon [polyamide]). The faces (also termed facing sections) may have
significant bending stiffness in addition to axial stiffness. The core (thermal barrier) is assumed to resist only shear.
The method has been compared with over 60 tests (using concentrated load on beams with P & DB polyurethane cores) and found to
predict trends in behavior and to produce reasonably consistent numerical results.
Refer to references [1], [2], [3], [6] and [8] in section 9.4 for details of the derivation of the final equations.
Note that Young's modulus (E) of the “exterior” and “interior” metal components (facing sections, or simply faces) is assumed to be
“large” compared to that of the core (elastomer). Thus only a very small error, on the safe side, is introduced in the analysis by
considering the metal pieces to alone carry flexural (bending) stresses. For 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 (10,000,000 psi). Thus, a 12 mm (1/2 in) wide elastomer element is only
0.39 mm (0.015 in) wide in terms of an equivalent piece of aluminum. In most cases this is small compared to other section dimensions.
This small difference could be addressed by including the core moment of “inertia” (times the elastomer-to-aluminum modular ratio),
but this has not been included in the method.
7.5.2.1 Load Due to Temperature Difference
A temperature difference between faces (and/or within a face) will cause bow (deflection), bending stresses and core shear stresses in
thermal barrier beams that are composite. There are no closed-form equations in this document to predict this behavior. Finite element
analysis (FEA) may, however, be used. With varying accuracy, two or three-dimensional (2-D or 3-D) general purpose, or 2-D special
purpose FEA, software is capable of predicting a response to a temperature gradient. Refer to references [4] and [6] for information on
special purpose FEA. Combined loading, consisting of wind and a given set of four temperatures (air side and core side of each face),
can also be modeled with FEA.
7.5.3 Variables
This section presents the variables needed as input for the design method. Refer to Figures 29a and 29b for illustration of most of these
quantities.
A Shear area of aluminum, which equals total (average) web thickness (tw) times net web height (h - g). See definitions for
other variables.
Ac Total cross section area of core (elastomer).
a Length of linearly increasing part of trapezoidal load.
a1, a2 Areas of faces 1 and 2.
b Average width of core (elastomer); b = Ac/Dc
b′ Clear opening between interlocks; usually the least width of the core.
c11, c22, D Distances between centroidal axis and air side surface of each face, and between axes, respectively.
Dc Cavity depth (maximum).
E Young's modulus of aluminum faces; 68,950 MPa (E = 107 psi = 104 ksi).
Ec Young's modulus of core (elastomer).
g Gap (clearance) between faces.
Gc Shear modulus of core (elastomer). [See discussion at end of input list].
h Overall depth of extrusion; h = c11 + D + c22
h1 , h2 Dimensions from extrusion's center of gravity to air side of faces 1 and 2
Io1, Io2 Moments of “inertia” (second area moments) of faces 1 and 2.
k Dimensionless ratio (a/L) for trapezoidal load.
L Span, center-to-center of supports.
P Concentrated load (force).
tw Thickness of strong axis web, or the total webs, of the aluminum extrusion. More generally, tw = Aw/(h-g) where Aw is the
sum of individual web thicknesses (in each face) times height of the pertinent facing section.
w Uniform load intensity (force/length).

wo Maximum intensity of triangular and trapezoidal load (force/length).
Consistent units are to be used throughout all equations.
7.5.3.1 Discussion on Shear Modulus Gc
Even if a test value of shear modulus for the core material alone is known, for core (thermal barrier) material specimens, it is necessary
to obtain a design value of Gc by comparing test beam results to predictions of effective moment of “inertia” (I'e) using various Gc
estimates. Refer to Section 7.2 for flexural test. This procedure results in a value of “effective” shear modulus, at least for a given
elastomer, cavity, and profiles with the same general shape. One way of aiding this determination of Gc is to plot the “predicted effective
I” versus “span L” for several values of Gc. By then plotting the test effective I at each of at least 2 spans, on the graph containing the
predicted value, an approximate (design) value of Gc can be determined.
Having determined an effective shear modulus, this modulus value may be used to design for other spans with that shape and with
“similar” shapes. Here “similar” refers especially to composite beams with the same cavity, core material and method of resisting
longitudinal shear. Deflection due to uniform, triangular or trapezoidal load may then also be calculated for various spans and “similar”
shapes, using the Gc value from the concentrated load tests.
The core material is assumed to be linearly elastic for the range of strain encountered in the core. As a starting point, (for urethanes), Gc
may be estimated to be between 0.33 Ec and 0.4 Ec, for constant temperature condition. Note that theoretically the value for Gc is at least
equal to Ec/3 and at most equal to Ec/2. As the elastomer Young's (tension) modulus Ec increases, the shear modulus is usually expected
to also increase. As shear modulus increases, the effective I of the beam would normally become less sensitive to variations in the value
of elastomer shear modulus Gc.
In order to address possible reduction in effective moment of “inertia” (I'e) at temperatures higher than room temperature (e.g., warmest
field conditions), it is recommended that I'e for a test beam at the appropriate elevated temperatures be measured. If the I'e is significantly
lower than at room temperature, then the same iterative calculation process may be used to find the appropriate (reduced) “average”
effective Gc for that temperature distribution in the elastomer. The value of Gc will be an average because the actual Gc may, in general,
vary with the core temperature. Core temperature varies through the depth of the core if the temperatures of the exterior and interior
faces differ. Note that the use of more than one value of span length to get a best estimate of Gc is recommended. If only one span length
is used, and it results in a “large” span-to-moment of inertia ratio, the change in I'e with various Gc values may be relatively small.
For the types of beams considered in this document, the existing test and analytical data [3] have shown that unloaded overhangs do not
significantly affect the behavior of simple span beams (with midspan concentrated load) for span/depth ratios of at least 20 and a shear
modulus of at least 552 Mpa (80 ksi.) Shear modulus values less than 552 Mpa (80 ksi) and/or span-to-depth ratios less than about 20,
may result in significant differences in stiffness of “overhang” versus “no overhang” beams. For such cases, other analytical methods
(e.g. finite element analysis using available software) should be used. Refer to [3], [4] and [6]. “Overhang” refers to an extension, past
the support, which is more than half the beam depth in length.
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 29A: Representative Drawing of Design Method Variables

FIGURE 29B: Representative Drawing of Design Method Variables

P
L
L/2
wo
L/2
L
Triangular
Concentrated
L
a=kL a
wo
wo
Uniform Trapezoidal
FIGURE 30: 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 to (2)
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 I′e, if (3)
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 30) 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 2 and 3
for 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 Io Ic
D0 0
(G )
2
p I
−P Ic PL 2
− ( wL ) Ic 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 2: 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 o a 2 Ic w o a 4
D0 + −
cG p I 6G p I 120EI
− w o LIc 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 − +
(
w o Ic w o Ic ( L − a ) w o −a + 2La − L
3 2 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 3: Constants D0 → D5
The expressions for F1 and F2, and for G1 and G2, are given in Table 4. 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
2G p I c ( e r + e − r )
Concentrated -F1
− w o Ic e− r
F1e2r
cG p I ( e r + e − r )
Uniform
−2w o Ic
c G p LI ( e r + e − r )
Triangular 1.5 -F1
− 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) F1 −
w o Ic e
-G1
2c1.5G p aI
TABLE 4: Expressions for Concentrated and Uniform Loads
*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 4 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
=
Uniform Load: Ie
wL4
=
( wL ) L3 (10)
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  EIe  S  AG 
Here the first term accounts for bending and the second term is for shear effects on the web(s). See Table 5 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)
( 5 − 4k 2 ) wo L
2
3 − 4k 2
TABLE 5: Values of B, S and P for the Four Load Types
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 ) 
Ie L2 A Ie
=
Uniform: I′e =
L A + 25.6Ie 1 +  25.6 ( Ie ) / ( L2 A ) 
2 (16)
 
Ie
Triangular: I′e =
1 + ( 26 23 ) ( Ie ) / ( L2 A ) 
(17)
Trapezoidal: Ie
I′e =
  4k 2  
 25.6 ( Ie ) 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 − EIo y′ ′ ) (19)
=f11 − Ec11 y′ ′
a 1D
and in face 2 (at distance c22 from centroidal axis 2) is:

M − EIo y′ ′ (20)
= f 22 + Ec 22 y′ ′
a 2D
Refer to Table 6 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
 3 
2
wox(3a [L – a] – x )/(6a) 0≤x≤a
TABLE 6: Expression for Maximum Moment
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 7 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 7: Expression for Maximum Shear
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=
Vc
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
To illustrate use of the equations, consider the following values (based on measurements, not the nominal die drawing dimensions) for
an AAMA test extrusion. Note that CAD software may be used to calculate section properties of faces 1 and 2. This example is given in
IP units only.
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 temperature of about 105°F with “exterior” aluminum maximum temperature about 160°F, “interior” aluminum  80°F,
and room air about 70°F.
a , I 1
1 o1
c
11
g DC
h
1
D
h
2 tw c 22
a , I
2 2 o2
FIGURE 31: Example Die Drawing with Dimensions
a1 = 0.2377 in2 I01 = 0.00188 in4 c11 = 0.1059"

a2 = 0.8222 in2 I02 = 0.6374 in4 c22 = 1.2763"
D = 1.9046"
Dc = 0.807" which is the maximum depth of the polyurethane.
tw = 0.107"
A = 0.3121 in2 = tw (h-g) = 0.107" (3.287" - 0.370") = web area
Ac = 0.355 in2 = 0.56" (0.37) + 2(0.062") (0.25) + 0.156" (0.375") = core area
g = 0.370" clear (gap)
b = 0.440" which is the “average width” = Ac/Dc = 0.355in2/0.807"
E = 10,000,000 psi = 10,000 ksi = Young's modulus of aluminum

Gc = (See tables for values considered
L = (See table) = span
P = 100 pounds; concentrated load at midspan
w = 100 pounds divided by span L; uniform load
Substituting in equations (1) to (4) for the various parameters:
Ic = 0.6689 in4
Io = 0.6393 in4
I = 1.3082 in4
Ic / I = 0.5113
Note that I = Ic + Io is the upper bound value of moment of “inertia” (second area moment) which would only be attained if there were
no shear deformations of the core or faces and no slip occurred. Io = Io1 + Io2 is the lower bound, which would apply if the faces were
free to slip along the core.
Effective Moment of Inertia:
Calculate deflection y from Eq. (8), and Ie from Eq. (9) and (10). First use expressions from Table 2 for D5 to D0 for concentrated and
uniform load, and expressions from Table 4 for F1 and F2. Now calculate y (at x = L/2) and Ie, at this maximum value of y. Next
compute I'e, using Eq. (15) and (16) respectively. Values are presented in Table 8 for several spans.
Effective Section Modulus:
Refer to Eq. (19) to (23), and appropriate expressions for maximum moment in Table 6, to calculate values of effective section moduli
Se1 and Se2. Values are given in Table 9.
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 entire section) would be approximately:
S1
= 1.3082 in4/1.5845" = I/h1
= 0.8256 in3 TOP ("exterior", face 1)
S2
= 1.3082 in4/1.7035" = I/h2
= 0.7679 in3 BOTTOM ("interior", face 2)
In other words the above values are the usual section modulus values from ordinary beam theory. These two values may be compared to
the effective section moduli (that include the effect of the polyurethane core, span and load type) in Table 9.
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 8: 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 9: 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 12: 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 32: Predicted Correction for Shear Deformation
TIR-A8-16 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 in TIR-A8-08 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
All definitions for this document were taken from AAMA AG-13, “AAMA Glossary.”
8.0 ATTACHMENTS
8.1 CANADIAN RESEARCH COUNCIL TEMPERATURE STUDY
CBD-47. Extreme Temperatures at the Outer Surfaces of Buildings

Originally published November 1963.
D.G. Stephenson
It is sometimes taken for granted that the variation in the outer surface temperature of a wall or roof will never exceed the range of
the outside air temperature. This ignores the influence of radiation and seriously under estimates the maximum temperatures that
building materials must withstand. This Digest discusses the effect on outside surface temperature of solar radiation, long-wave
radiation, surface colour, the position and colour of adjacent surfaces, temperature of the air inside and outside the building, and the
thermal properties of materials used to form a building envelope.
The most direct way of determining the temperatures that actually occur in buildings is to measure them. This approach is quite
impractical, however, when the purpose is to find the extreme temperatures that any wall or roof surface may experience; this would
require a long series of observations on structures with every combination of wall and roof construction, surface colour, orientation
and location. Instead, the heat exchange at the outside surface of a wall or roof can be analysed and the factors that influence the
surface temperature can be studied separately. With these data it is possible to predict the temperatures that will obtain under any
specified circumstances.
Thermal Radiation
All objects continuously emit radiation and absorb some of the radiation from other bodies that is incident on them. Emission and
absorption of radiation play a large part in the energy exchange at the outer surface of a building.
The wave-lengths of the thermal radiation depend on the temperature of the emitting surface - the higher the temperature the shorter
the wave-length at which the maximum energy occurs. The absolute temperature of the outer layers of the sun's atmosphere is about
twenty times as great as the temperature of the surface of the earth and terrestrial objects such as buildings. The energy in solar
radiation is concentrated, therefore, at much shorter wave-lengths than occur in the radiation from low-temperature bodies. Thus
solar radiation is generally referred to as "shortwave" and radiation from terrestrial objects as 'long-wave."
The rate of energy emission from unit area of a surface depends on the fourth power of the absolute temperature of the surface and
on the nature of the surface, which is characterized by the value of the emissivity. The value of the emissivity also indicates the
propensity of the surface to absorb radiation of the same wave-length as that it emits. The absorptivity of a surface for short-wave
radiation, a, is not, in general, equal to its absorptivity for long-wave radiation. The change in absorptivity with wave-length can
sometimes be exploited to reduce the maximum temperatures that occur at the surface of bodies exposed to the sun. This is discussed
later under the effects of colour.
Heat Balance at a Surface
At every instant the total heat leaving a surface must be equal to the total heat approaching the surface. Figure 1 shows the various
components of the heat flow toward and away from an opaque surface. For the surface of a building exposed to solar radiation the
various heat flows will be in the directions shown in the figure. The temperature of the surface is always at the value where the heat
gains and losses balance. If the solar radiation incident on a surface increases, the surface temperature rises, causing conduction,
convection and long-wave radiation to increase just enough to offset the increased rate of energy absorption.
Figure 1. Components of heat balance at an opaque surface.
Calculation of the surface temperature and heat flux can be greatly simplified through the use of the sol-air temperature concept. The
S. A. T. is the fictitious temperature of the outside air that would produce by convection alone the same rate of heat exchange at the
surface as actually occurs by convection and long and short-wave radiation combined. Thus
q = h (S. A. T. - ts);
combining this definition of S. A. T. with the energy balance at the surface gives
aS eL E Ts4
S. A. T. = tA + + -
h h h
The temperature of the outside surface of a wall or roof with negligible heat storage capacity can be determined by the graphical
method described in CBD 36, using S. A. T. as the outside temperature and h as the outside surface conductance. Figure 2 gives the
magnitudes of the different components of S. A. T. and shows how the roof conductance and inside temperature affect the outside
surface temperature. The values used for this example are appropriate for a dark coloured, flat roof in the region between 40 and 50
degrees north latitude, at a time when the surface temperature would be a maximum. The indicated surface temperature of 190°F
represents the highest temperature a dark roof with an unobstructed view of the sky is likely to attain in any part of Canada.
Figure 2. Summer temperature for dark roof with unobstructed view of sky.
The short-wave irradiation S may include reflected radiation from adjacent surfaces, depending on their colour, proximity and the
irradiation they receive, as well as the radiation that comes directly from the sun and sky. The value of the long-wave radiation, L, is
likewise dependent on the surrounding surfaces that can be seen from the surface in question. For example, the roof of a low building
situated directly south of a much higher building will receive a considerable amount of reflected sunlight, plus some fraction of the
long-wave radiation emitted by the wall of the higher building. The maximum temperature of a dark horizontal roof situated close to
the south wall of a very high building could be as high as 230°F.
Vertical Surfaces
The annual maximum insolation is nearly the same for all walls facing not more than 90 degrees from south, regardless of latitude.
The hour and date of the maximum depend, however, on the wall orientation and latitude. Walls facing east and west receive their
greatest irradiation in the middle of the summer about 4 hours before and after noon, respectively, whereas those facing south receive
their maximum at noon about the middle of November. Walls facing east and west will have higher surface temperatures than walls
facing south, other things being equal, because their maximum irradiation coincides with the maximum ambient air temperature.
Walls always receive some reflected shortwave radiation from their surroundings. They also receive more long-wave irradiation than
flat roofs because at least half their field of view is below the horizon where the intensity of long-wave irradiation is always greater
than that from the sky. Thus the total radiation incident on a vertical surface is just about the same as that shown in Figure 2 for a flat
roof. A surface temperature of 190°F, therefore, is the maximum a dark coloured wall is likely to attain.
Effect of Heat Storage
It is commonly recognized that the surface of a thick masonry wall does not become as hot during a clear summer day as the outer
layer of a light curtain wall section, if both walls have the same exposure. The difference lies in the heat storage capacity of the
walls.
When the radiation incident on a wall or roof surface suddenly changes, as when a cloud moves away from in front of the sun, the S.
A. T. increases abruptly, but the temperature of the exposed surface does not reach a new equilibrium value until some time later.
The time required depends on the value of the surface conductance and the heat storage capacity of the wall or roof. Lightweight
walls reach equilibrium in a fraction of an hour; very heavy walls require more than a day. The temperatures indicated by the straight
line on Figure 2 are the equilibrium values. Even on a cloudless day the S. A. T. is never constant, because solar radiation
continuously changes from sunrise to sunset. Around midday, when the solar radiation on a horizontal surface is maximum, the S. A.
T. changes very little in a period, of an hour so that the surface of a lightweight roof could reach the maximum temperature of 190°F
shown in Figure 2. The maximum surface temperature for a massive slab with the same total thermal resistance would be somewhat
lower. The precise calculation of surface temperature, allowing for heat storage capacity, is quite involved and a detailed discussion
is beyond the scope of this Digest. It is perfectly correct to say, however, that the temperatures at various points throughout a
building enclosure will never exceed the values that would obtain at equilibrium with the maximum S. A. T. Thus the straight line on
Figure 2 represents the upper limits for the temperatures everywhere through the roof.
The Effect of Surface Colour
The fraction of the solar irradiation absorbed by a surface depends primarily on its colour. A white surface absorbs about 40 per cent,
whereas dark green, brown and black surfaces absorb about 90 per cent. Figure 2 shows the extent to which the S. A. T. for a surface
depends on the magnitude of the absorbed short-wave radiation. If the roof considered in Figure 2 had a white instead of black
surface (i.e. a = 0.4 instead of 0.9) the surface temperature would be 130°F instead of 190°F. The difference between the maximum
temperatures of black and white vertical surfaces is about 50 F degrees compared with 60 F degrees for horizontal surfaces.
The aptness of these calculated values has been corroborated by measurements made on a building in Ottawa. The opaque parts of
the wall were lightweight panels, black on one side and white on the other. They were originally installed with the black side out, but
as an experiment two panels in the middle of a south-west wall were reversed so that the white surface was outside. During one
summer the observed maximum temperature of the outer black surface was 175°F, while that of the adjacent white panel was 130°F.
Unpainted metal surfaces that are not heavily oxidized reflect about the same fraction of incident short-wave radiation as a white
painted surface, but their emissivity is only one quarter the value for a painted surface. Consequently, the radiation emitted by an
unpainted metal surface is much less than that for a painted surface and its surface temperature is higher, therefore, than that for a
similarly exposed white painted surface. It is for just this reason that most airlines have the upper half of the fuselages of their
aircraft painted white and the under surfaces unpainted. An aircraft parked in the sun is significantly cooler when painted this way
than if it is completely unpainted or completely painted.
Low Temperature Extremes
The foregoing discussion has been concerned only with the annual maximum S. A. T. and the resultant maximum surface
temperature. A building designer also needs to know the minimum temperature that can occur so that he can allow for thermal
expansion effects and condensation within the wall or roof. Minimum surface temperature occurs when there is no solar radiation,
the ambient air temperature is at a minimum, there is no wind and the sky is clear. Under these conditions the S. A. T. is well below
ambient air temperature and the surface of an insulating roof may be about 10 degrees cooler than ambient air temperature. In this
case the energy leaving the surface in the form of long-wave radiation is equal to the sum of the heat conducted through the material
backing the surface, the convection from the outside air to the surface and the fraction of the long-wave radiation from the sky that is
absorbed by the surface. The frost that forms on the windshield of a car left out on a clear calm night is a good demonstration that
surfaces exposed to a clear sky do, in fact, fall well below the temperature of the air. As walls receive more long-wave irradiation
than flat roofs, they have a minimum outer surface temperature only slightly below the minimum air temperature. The colour of the
outer surface has no appreciable effect on minimum surface temperature because all paints have nearly the same value of emissivity.
Painted surfaces will always have lower minimum temperatures, however, than similarly exposed unpainted metal.
Conclusion
The maximum temperature of the outer surface of any building depends mainly on its colour and orientation. The colour and
proximity of neighbouring surfaces also have a significant effect on surface temperature. Analysis has shown that dark roof surfaces
may reach temperatures of the order of 230°F in summer and fall a few degrees below the minimum air temperature in winter. It is
important, therefore, to be sure that any proposed roofing system with a dark surface can operate satisfactorily at temperatures
varying between -50 and 230°F. If a light coloured surface is used to reduce the maximum temperature it is important to be sure that
the surface will retain a low value of short-wave absorptivity over its entire service life.
The maximum temperature for a wall surface is between 140 and 190°, depending on colour and proximity to reflecting surfaces. If
external shading devices are used they should have a dark surface that will absorb the radiation incident on them rather than reflect it
onto adjacent wall or window surfaces. It is important, however, not to darken the colour of an outer surface until it has been
established that its new shade will not cause the temperature of the wall materials to exceed their allowable values.
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)
(0.125 in) COMBINATION SHEAR
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 33: Combination Shear Torsion and Impact Test Fixture Schematic

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 34: Tensile Test Fixture Schematic

9.0 REFERENCES
9.1 References to the standards listed below shall be to the edition indicated. Any undated reference to a code or standard appearing
in the requirements of this standard shall be interpreted as to referring to the latest edition of that code or standard.
9.2 American Architectural Manufacturers Association (AAMA)
ANSI/AAMA/WDMA 101/I.S.2/NAFS-11, Voluntary Performance Specification for Windows, Skylights and Glass Doors
AAMA 505-09, Dry Shrinkage and Composite Performance Thermal Cycling Test Procedure
AAMA 507-15, Standard Practice for Determining the Thermal Performance Characteristics of Fenestration Systems Commercial
Buildings
AAMA 1503-09, Voluntary Test Method for Thermal Transmittance and Condensation Resistance of Windows, Doors and Glazed
Wall Sections
AAMA MCWM-1-89, Metal Curtain Wall Manual
AAMA QAG-1-98, Quality Assurance Processing Guide for Poured and Debridged Polyurethane Thermal Barriers
AAMA SFM-1-87, Aluminum Storefront and Entrance Manual
9.3 ASTM International (ASTM)
ASTM C177-13, Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means
of the Guarded-Hot-Plate Apparatus
ASTM C236-89(1993)e1, Standard Test Method for Steady-State Thermal Performance of Building Assemblies by Means of a
Guarded Hot Box
ASTM C518-15, Standard Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter
Apparatus
ASTM D256-10e1, Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics
ASTM D638-14, Standard Test Method for Tensile Properties of Plastics
ASTM D 648-16, Standard Test Method for Deflection Temperature of Plastics Under Flexural Load in the Edgewise Position
ASTM D695-15, Standard Test Method for Compressive Properties of Rigid Plastics
ASTM D696-16, Standard Test Method for Coefficient of Linear Thermal Expansion of Plastics Between -30°C and 30°C With a
Vitreous Silica Dilatometer
ASTM D790-15e2, Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating
Materials
ASTM D792-13, Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement
ASTM D2240-15, Standard Test Method for Rubber Property—Durometer Hardness
ASTM E283-04(2012), Standard Test Method for Determining Rate of Air Leakage Through Exterior Windows, Curtain Walls, and
Doors Under Specified Pressure Differences Across the Specimen
ASTM E330/E330M-14, Standard Test Method for Structural Performance of Exterior Windows, Doors, Skylights and Curtain
Walls by Uniform Static Air Pressure Difference
ASTM E331-00(2016), Standard Test Method for Water Penetration of Exterior Windows, Skylights, Doors, and Curtain Walls by
Uniform Static Air Pressure Difference
ASTM E529-04(2011), Standard Guide for Conducting Flexural Tests on Beams and Girders for Building Construction
ASTM E575-05(2011), Standard Practice for Reporting Data from Structural Tests of Building Constructions, Elements,
Connections, and Assemblies
9.4 OTHER APPLICABLE REFERENCES
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.
9. D.G. Stephenson, (1963), “Extreme Temperatures at the Outer Surfaces of Buildings,” Canadian Building Digest, CBD-47.
Changes from AAMA TIR-A8-08 to AAMA TIR-A8-16

- Various editorial changes were made
- Added new figures: 2b, 13, 21b, 24, 27, 28, 29b,
- Updated figures: 5 and 9
- Updated the shore hardness requirement in section 4.3.4
- Removed information to contact Mr. Hartsock, he is no longer available
- Dual cavity is added to the document
- Added instructions for testing dual cavities to 7.3.2
American Architectural Manufacturers Association

1827 Walden Office Square, Suite 550
Schaumburg, IL 60173
PHONE (847)303-5664
EMAIL webmaster@aamanet.org
WEBSITE www.aamanet.org

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American Architectural Manufacturers Association

2.3 Definition of Framing with a Structural Thermal Barrier

FIGURE 1 – Typical Poured and Debridged Thermal Barrier Aluminum Extrusion

2.3.1 Definition of Poured and Debridged Design

AAMA TIR-A8-16 Page 1

2.3.2 Definition of Mechanically Locked Design

FIGURE 3: Typical Mechanically Crimped In Place Thermal Barrier Extrusions

AAMA TIR-A8-16 Page 2

FIGURE 4: Typical Mechanically Crimped In Place Thermal Barrier Composite Section

2.4.1 History of Poured and Debridged Thermal Barriers

2.4.2 History of Mechanically Locking Thermal Barriers

AAMA TIR-A8-16 Page 3

3.0 THERMAL BARRIER MATERIALS

6. It must be designed so as to minimize dry shrinkage. (If applicable.)

4.0 DESIGN GUIDELINES

4.1.1 Poured in Place Cavity Design

FIGURE 5: Poured in Place Cavity Design

IRREGULAR CUT - USUALLY

FIGURE 6: Pour and Fill

CUTTING TOO DEEP BRIDGE NOT REMOVED

FIGURE 7: Pour and Fill

FIGURE 8: Extruded Cavity

AAMA TIR-A8-16 Page 7

FIGURE 9: Standard and Conceptual Cavity Designs and Data

AAMA TIR-A8-16 Page 8

4.1.2 Mechanically Locked, Preformed Thermal Barriers, Cavity Design

FIGURE 10: Typical Thermal Barrier Cavity

Knurling of the Aluminum Cavity

FIGURE 11: Knurl on the Aluminum Cavity

AAMA TIR-A8-16 Page 9

Rolling of the Aluminum-Thermal Barrier Composite

FIGURE 12: Crimping Roller Alignment

AAMA TIR-A8-16 Page 10

4.1.3.1 Poured and Debridged Shrinkage

4.1.3.2 Mechanical Locking Shrinkage

4.1.3.3 Aluminum Cavity Distortion

Distortion can be the result of a number of contributing factors:

1. Cavity size and shape

FIGURE 13: Mechanical Locking

4.1.3.4 Mechanical Locking Distortion of Aluminum

Step 2 – Crimping of the Aluminum Extrusions

Step 3 – Profile Correction Stage

4.2 Cavity Surface Treatment

4.2.1 Poured in Place Materials

Anodic Finish Sealing Processes

4.2.2 Mechanically Locked, Preformed Profiles

4.3 Manufacturing Poured and Debridged Thermal Barriers

4.3.1 Material Processing

FIGURE 14: Taped Extrusions Before Pouring (When required)

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

4.3.1.4 Gel Life