| Glass-Fiber-Reinforced Polyamide 6.6 | Approximately 0.25–0.35 | Typical tensile strength: 70–120 MPa; compressive performance depends strongly on fiber content, geometry, and orientation. | Approximately −30°C to +120°C for common building-system grades. | Good dimensional stability when properly designed; polyamide absorbs moisture, which can affect dimensions and mechanical properties. | Fire classification varies by formulation. Halogen-free and flame-retardant grades should be specified where required. | Continuous insulating strips, reinforced profiles, and mechanically locked thermal separators. | Aluminum windows, doors, curtain walls, and façade systems requiring a balance of strength, processability, and thermal performance. | Moisture conditioning, profile geometry, fastener placement, and installation tolerances must be included in structural and thermal calculations. |
| Rigid Polyurethane Foam | Approximately 0.020–0.030 | Typical compressive strength: 0.15–0.40 MPa at approximately 10% strain; not suitable for high-load structural transfer without reinforcement. | Approximately −40°C to +90°C; temperature capability depends on density and formulation. | Low water absorption in closed-cell forms, but joints, surface damage, and prolonged moisture exposure can reduce performance. | Combustible unless specially formulated and protected. Fire classification must be verified for the complete assembly. | Pour-and-debridge cavities, insulated cores, and injected thermal barriers within aluminum profiles. | High thermal resistance in windows, doors, and façade profiles where the material is protected inside a closed cavity. | Lower mechanical capacity, aging, expansion, adhesion, and fire behavior require project-specific testing and quality control. |
| Pultruded Glass-Fiber-Reinforced Polymer | Approximately 0.30–0.50 | Typical tensile strength: 300–800 MPa; compressive strength commonly ranges from 200–500 MPa, depending on fiber architecture and resin. | Approximately −40°C to +120°C; resin selection controls the upper limit. | Very good resistance to corrosion and moisture. Long-term creep and resin aging should be evaluated for sustained loads. | Resin-dependent. Fire-retardant formulations can improve performance, but the complete façade or frame assembly must be assessed. | Structural isolator bars, composite pressure plates, reinforced brackets, and load-bearing thermal separators. | High-load curtain walls, unitized façades, rainscreens, and projects exposed to aggressive or marine environments. | Higher cost and more specialized fabrication; thermal conductivity is higher than foam, so geometry and contact bridges remain important. |
| Phenolic or Glass-Fiber-Reinforced Thermoset Laminate | Approximately 0.20–0.35 | Typical compressive strength: 250–500 MPa; suitable for rigid, thin isolating components when properly supported. | Approximately −40°C to +120°C or higher for selected grades. | Generally good moisture resistance and low creep; edges and drilled areas require appropriate detailing. | Often favorable for smoke and flame performance compared with many thermoplastics, but certification is formulation-specific. | Thin structural plates, bearing pads, fastener isolators, and high-strength connector separators. | Structural façade connections, curtain-wall brackets, window hardware, and interfaces requiring a rigid low-conductivity plate. | Brittleness, machining dust, limited impact resistance, and possible delamination must be controlled during fabrication and installation. |
| EPDM or Silicone Elastomer | Approximately 0.20–0.35 | Low structural capacity; typically used for gaskets, seals, setting blocks, and vibration-isolating interfaces rather than primary load transfer. | EPDM: approximately −50°C to +120°C; silicone grades may operate over a wider range. | Excellent weathering and UV resistance when the correct grade is selected; compression set must be considered. | Fire and smoke properties vary widely. Fire-rated grades and tested joint systems may be required. | Gaskets, continuous seals, glazing wedges, thermal pads, and resilient separators. | Glazing systems, perimeter seals, expansion joints, and secondary thermal or airtightness interfaces. | Not normally suitable as the sole structural thermal break; compression set, joint movement, and compatibility with adjacent materials are critical. |
| Microporous Silica Aerogel Blanket or Panel | Approximately 0.013–0.025 | Low to moderate compressive capacity; usually requires a protective facing or separate structural support. | Typically approximately −50°C to +200°C, depending on binder, facing, and product construction. | Hydrophobic grades resist liquid water, but cutting, compression, and mechanical damage can reduce insulation performance. | Often non-combustible or low-combustibility in mineral-based constructions; classification must be confirmed for the specific product. | Thin insulation inserts, thermal pads, cavity liners, and retrofit infill around difficult connection details. | Space-limited retrofit work, high-performance façades, steel-to-envelope junctions, and areas requiring maximum insulation in minimal thickness. | Higher cost, dust during cutting, limited structural use, and sensitivity to compression or poor edge detailing. |
| High-Density PVC or Rigid Thermoplastic Profile | Approximately 0.14–0.20 | Typical tensile strength: 40–60 MPa; stiffness and long-term load capacity are lower than reinforced polyamide or composite materials. | Approximately −20°C to +60°C for many building applications. | Very low water absorption and good corrosion resistance; thermal expansion can be significant. | Formulation-dependent. Flame-retardant grades are available, but smoke and fire requirements must be checked. | Extruded isolator strips, spacer profiles, and non-primary-load separators. | Low- to medium-load windows, interior interfaces, and cost-sensitive applications with moderate temperature exposure. | Creep, ultraviolet exposure, thermal expansion, and limited high-temperature performance can restrict use in large or heavily loaded façades. |
| Stainless-Steel or Aluminum Thermal Break with Insulating Inserts | Metal itself is highly conductive; system performance is created by reducing metal cross-section and adding a low-conductivity insert. | High mechanical strength and excellent resistance to wind, impact, and connection loads; performance depends on the metal section and insert design. | Metal can tolerate wide temperature ranges; insert material usually controls the assembly limit. | Excellent durability when corrosion-resistant alloys, drainage, and compatible materials are correctly specified. | Metal components are generally non-combustible; inserts, coatings, seals, and adjacent materials still require fire assessment. | Thermally broken brackets, point connections, pressure plates, and reduced-section structural nodes. | High-rise curtain walls, heavy façades, balconies, sunshades, and projects requiring high connection strength. | Point bridges can remain significant. Three-dimensional thermal-bridge calculations and condensation checks are often necessary. |
