The continuous pursuit of higher energy efficiency is driving Air Handling Unit (AHU) manufacturers to develop and implement innovative solutions that enhance the overall energy performance of their equipment. One such solution is the use of thermal bridge-free casing technology.
By eliminating thermal bridges, this technology significantly improves the thermal performance of the AHU casing. This is particularly important in applications serving facilities with stringent hygiene requirements, where temperature stability and condensation control are essential.
What Are Thermal Bridges?
A thermal bridge is a location within a structure where heat transfer is locally increased compared to the surrounding areas. In practice, this means that heat escapes more readily through these sections of the casing.
In Air Handling Units, thermal bridges are typically created by metallic components that provide a continuous conductive path between the interior and exterior of the unit.
At low ambient temperatures, thermal bridges also reduce the internal surface temperature of the casing, increasing the risk of surface condensation.
The most common locations where thermal bridges occur in Air Handling Units include:
- structural frame profiles,
- fastening components (such as bolts, screws, and hinges),
- joints between casing panels.
Thermal bridges may result in:
- increased heat losses,
- condensation on the casing surface,
- reduced thermal insulation performance,
- the growth of mould and microorganisms.
What Is Thermal Bridge-Free Technology?
Thermal bridge-free technology is based on eliminating continuous thermally conductive paths between the inside and outside of the Air Handling Unit.
In other words, the casing design prevents direct heat transfer through highly conductive materials connecting the internal and external environments.
Typical conductive paths are formed by structural components made of steel or aluminium. These thermal bridges are interrupted by integrating materials with low thermal conductivity, such as high-performance polymer thermal breaks, insulating foam, or composite materials.
Key Design Features Used in Clima Gold Air Handling Units
- Aluminium structural profiles incorporating engineered polymer thermal breaks, effectively interrupting conductive heat transfer.
- Double-skin sandwich panels consisting of inner and outer steel sheets with mineral wool insulation, incorporating dedicated thermal break components that minimise heat transfer through the casing structure.
Applications of Thermal Bridge-Free Technology
Thermal bridge-free Air Handling Units are most commonly specified for facilities where maximum energy efficiency and strict hygienic standards are required, including:
- healthcare facilities,
- hospitals,
- laboratories,
- food processing plants,
- pharmaceutical manufacturing facilities,
- server rooms,
- data centres.
However, this technology is equally beneficial in commercial, industrial, and public buildings, where it contributes to improved energy efficiency, enhanced indoor comfort, and extended equipment service life.
Benefits of Thermal Bridge-Free Technology
Improved Energy Efficiency
Eliminating thermal bridges significantly reduces the overall thermal transmittance (U-value) of the casing.
Thermal bridge-free casings can achieve Thermal Class T1 or T2 in accordance with EN 1886, resulting in lower heating and cooling energy demand throughout the year.
Condensation Protection and Extended Equipment Lifetime
Removing thermal bridges eliminates local cold spots on the casing surface, substantially reducing the risk of condensation.
This improves hygienic performance, protects the casing against corrosion, reduces maintenance requirements, and extends the operational life of the Air Handling Unit.
Enhanced Hygienic Performance
By preventing surface condensation, thermal bridge-free construction significantly reduces the risk of mould, bacteria, and other microorganisms developing within the AHU casing.
This makes the technology particularly suitable for applications requiring the highest standards of indoor air hygiene.
Summary
The implementation of thermal bridge-free technology in Clima Gold Air Handling Units optimises the casing design by eliminating linear thermal bridges while maintaining structural rigidity and unrestricted service access.
This advanced construction enables the casing to achieve Thermal Class T1–T2 in accordance with EN 1886, without compromising mechanical strength or maintainability.
By carefully controlling the continuity of conductive materials and incorporating components with low thermal conductivity, the casing minimises localised condensation, reduces long-term material degradation, and ensures stable thermal performance throughout the entire service life of the Air Handling Unit.
