Mitigate Thermal Bridging: Fluid Applied Thermal Break Solutions

Introduction

In today’s high-performance building landscape, managing thermal bridges is no longer optional — it’s essential for achieving optimized energy efficiency, moisture control, and overall occupant comfort. As the independent representative agency resource in high-performance coatings, Atlantic Coating Consultants (ACC) is pleased to spotlight solutions like Tnemec Series 971 Aerolon — the industry’s most effective fluid-applied thermal break coating. This blog will explore what thermal bridging is, why it matters, and how fluid-applied systems like Aerolon bring significant advantages for architects, engineers, building owners, and contractors.

What is a Thermal Bridge?

A thermal bridge occurs when a conductive component directly ties the building’s conditioned interior to the unconditioned exterior (or vice versa), bypassing the insulating envelope. A thermal bridge occurs when a conductive building material bypasses a building’s thermal envelope without separating or breaking the component from conditioned to unconditioned space.

Common locations include steel framing penetrations, balcony slabs, cantilevers, roof penetrations and mechanical attachments that extend through the building envelope.

Why does this matter? Thermal bridges undermine overall wall or roof assembly R-value, and create potential condensation risk when surface temperatures fall below the dew-point inside the building envelope. When a surface inside the envelope drops below the internal air dew point (for example ~44 °F for 70 °F/40% RH conditions), condensation can form — leading to moisture intrusion, mold growth, and thermal performance loss.

Traditional Thermal Break Methods

Historically, thermal breaks in structural assemblies have relied on materials like thermal pads, bushings, washers, or special structural discontinuities inserted between conductive metal components. While effective, such solutions often involve additional fabrication, complicated detailing, extra labor, and sometimes require structural re-engineering or thicker assemblies.

Enter Fluid-Applied Thermal Break Coatings

Fluid-applied thermal break coatings represent a streamlined alternative: rather than inserting discrete break components, a spray applied material is integrated into the surface of the conductive element to interrupt the conduction path.

Key benefits include:

• Simpler detailing — less need for custom steel fabrication or bushings

• Ability to conform to complex shapes, penetrations or irregular geometry

• Reduced on-site labor and coordination (especially beneficial in structural steel or retrofit applications)

• Enhanced thermal performance by reducing conductive heat flow directly through structural elements.

  
  

Why Tnemec Series 971 Aerolon Stands Out

As the industry’s moste effective fluid-applied thermal break coating, Tnemec Series 971 Aerolon brings years of proven performance, and reliability to the table. Aerolon offers a thermal conductivity (k-value) under 40 mW/m·K — an extremely low value compared to typical structural steel conduction paths — which helps slow thermal transfer helping to keep surface temperature above the dew point.

Some highlights:

• Specifically formulated for thermal-bridge interruption rather than just general coating service.

• Applicable to vertical wall steel, canopies, roof penetrations, mechanical dunnage, concrete slabs or other structural features where conduction is a concern

• Proven track record

• Helps reduce risk of condensation, mold, and thermal performance loss — bringing both energy, comfort and durability benefits.

• Reduced installation cost.

  
  

Application Considerations & Specifying Tips

When specifying or applying a fluid-applied thermal break coating like Aerolon, consider the following:

1. Substrate preparation – The conductive element (steel, concrete, etc.) must be properly cleaned, primed (if required) and prepared per manufacturer guidance to ensure adhesion and performance.

2. Detailing extent –The thermal break material is typically installed 18″-24″ on either side of the thermal envelope — ensuring the conduction path is fully interrupted.

3. Thickness / film build – Verify the manufacturer’s specified film thickness needed to achieve the desired thermal performance and durability.

4. Compatibility with adjacent systems – Ensure the thermal break coating integrates with primary waterproofing, cladding anchor systems, flashings and other aspects of the envelope without causing conflicts.

5. Inspection & quality control – Because the thermal break coating becomes part of the structural/thermal assembly, documenting application thickness, continuity, adhesion and coverage is critical for performance assurance.

6. Coordination with structural steel & contract documents – Make sure the structural drawings, coating specification, and thermal/energy modelling all align — especially since fluid-applied breaks may allow simplified steel detailing compared to traditional breaks.

7. Durability & environment – Choose a coating rated for the environment (exterior, interior, exposure to moisture, temperature cycling) and integrate with long-term maintenance plans.