Thermal Break Pour and Debridge Inspection

Inspection template for thermally improved aluminum window frame extrusions to verify polyurethane pour fill, cure, and debridging quality for a continuous thermal barrier.

Inspection Setup and Lot Identification

• Work order, profile, and lot identification match the production traveler
• Inspection stage confirmed as pre-cure, post-cure, or post-debridge
• Reference work instruction or SOP available at point of use
• Inspector name or badge ID
• Inspection date and time

Polyurethane Pour Fill and Coverage

• Thermal break cavity fully filled with polyurethane along the inspected length
• No visible voids, gaps, skips, or unfilled sections in the pour
• Pour bead is continuous and centered within the thermal break channel
• Polyurethane material identification and batch/lot traceability recorded
• Observed pour defects count
• Any evidence of contamination, discoloration, or foreign material in the pour

Cure Condition and Thermal Break Integrity

• Polyurethane is fully cured per process specification before handling or debridging
• Surface is firm, non-tacky, and free from deformation when lightly inspected
• Thermal barrier shows no separation, cracking, shrinkage, or pull-away from the aluminum extrusion
• Cure time since pour
• Ambient temperature at inspection

Debridging Quality and Metal Separation

• All intended metal bridges have been removed to create a non-metal-to-metal barrier
• No residual metal shavings, burrs, or bridge remnants remain in the thermal break area
• Debridging cut or removal line is clean and does not damage the polyurethane barrier
• Measured residual bridge thickness or remaining metal contact
• Debridging defects count

Final Condition, Documentation, and Disposition

• Finished extrusion meets visual acceptance criteria for thermal break workmanship
• Non-conformances documented with location, defect type, and disposition
• Disposition selected for the lot or part
• Inspector comments and follow-up actions