Thermally Broken Mullions: Why the Thermal Break Drives Facade Performance
The thermal break decides whether an aluminum mullion is part of the envelope or part of the problem The broader aluminum mullion extrusion guide covers the surrounding choices, but the thermal break is the point where performance becomes non-negotiable. Alloy, depth, finish, and geometry all matter, yet none of them can compensate for a profile that behaves like a continuous heat bridge. That is the reason thermal-break decisions deserve more attention than they usually get in design meetings. A mullion can look structurally sound on paper, pass basic section checks, and still perform poorly once it is locked into a conditioned building. The failure mode is not dramatic. It shows up as cold perimeter surfaces, winter condensation, draft complaints, stained interior finishes, and energy bills that never match the promise of the design. ...