Design Calculations of Lightning Protection Systems – Part Fifteen

In Article " Design Calculations of Lightning Protection Systems – Part Two ", I indicated the lightning
protection design process involves a number of design steps as in Fig.1.

Fig.1: The Lightning Protection Design Process

Step#1: Characteristics of the Structure to Be Protected

Explained in above Article
 Step#2: Risk Assessment Study

Also, In above Article, I indicated that the risk assessment study can be done by (4) different methods as
follows:

Methods Of Calculations
For Risk Assessment
Study
First: Manual Method
(Equations And Tables
Method) as per IEC
62305-2
First: Manual Method
(Equations And Tables
Method) as per NFPA 780
Second: Software Method
For Performing The Risk
Assessment Study
Third: Excel Sheets
Method For Performing
The Risk Assessment
Study
Articles
Design Calculations of Lightning Protection Systems –
Part Two
Design Calculations of Lightning Protection Systems –
Part Three
Design Calculations of Lightning Protection Systems –
Part Four
Design Calculations of Lightning Protection Systems –
Part Five
Design Calculations of Lightning Protection Systems –
Part Six
Design Calculations of Lightning Protection Systems –
Part Seven
Design Calculations of Lightning Protection Systems –
Part Eight
Design Calculations of Lightning Protection Systems –
Part Nine
Design Calculations of Lightning Protection Systems –
Part Ten
Design Calculations of Lightning Protection Systems –
Part Eleven
Design Calculations of Lightning Protection Systems –
Part Twelve
Design Calculations of Lightning Protection Systems –
Part thirteen

Fourth: Online
Calculators Method Used Design Calculations of Lightning Protection Systems –
for Need for Lightning Part Fourteen
Protection calculations

Today, I will I will continue explaining other steps of Lightning Protection Design procedure.

For more information, please review the following Articles:

 Design Process for Lightning Protection Systems

 Design Calculations of Lightning Protection Systems – Part One
 Step#3: Selection Of External LPS Type and Material

1- The Correct Choice Of Lightning Protection Components (LPC)

 The correct choice of material, configuration and dimensions of the lightning

protection components is essential when linking the various elements of an LPS
together.
 The designer/user needs to know that the components, conductors, earth
electrodes etc will meet the highest levels when it comes to durability, long term
exposure to the environmental elements and perhaps most importantly of all, the ability
to dissipate the lightning current safely and harmlessly to earth.
 Various standards series have been compiled with this very much in mind. At
present these standards are as follows:

Standards for Lightning Protection Systems

1- Within Europe:

Various standards series have been issued by (2) National Committees which are:
 1. The European Committee for Electrotechnical Standardisation (CENELEC).
2. The International Electrotechnical Commission (IEC)

The CENELEC has released the EN 50164 series of standards. The EN 50164 series are
component standards to which the manufacturers and suppliers of lightning protection
components should test their products to verify design and quality.

The EN 50164 series currently comprises of:

 EN 50164-1 Lightning protection components (LPC) – Part 1: Requirements for

connection components
 EN 50164-2 Lightning protection components (LPC) – Part 2: Requirements for
conductors and earth electrodes
 EN 50164-3 Lightning protection components (LPC) – Part 3: Requirements for
isolating spark gaps
 EN 50164-4: Lightning Protection Components (LPC) – Part 4: Requirements for
conductor fasteners
 EN 50164-5: Lightning Protection Components (LPC) – Part 5: Requirements for
earth electrode inspection housings and earth electrode seals
 EN 50164-6: Lightning Protection Components (LPC) – Part 6: Requirements for
lightning strike counters
 EN 50164-7: Lightning Protection Components (LPC) – Part 7: Requirements for
earthing enhancing compounds

Notes:

 The standards generally have an IEC prefix to their number (CEI for French
versions). IEC standards are produced in English and French languages.
 IEC and CENELEC generally work in parallel, and CENELEC members vote to adopt
new IEC standards as CENELEC standards. The committees of CENELEC may choose to
make some alterations to the IEC version.
 Additionally, CENELEC produce their own standards to which IEC have no
counterpart. CENELEC documents are produced in English, French and German and an
approved CENELEC standard will have an EN prefix (or NE in the French language
versions).

For example:

IEC 62305-1 (IEC version) is parallel to EN 62305-1 (CENELEC adopted copy of the above)
And both are parallel to BS EN 62305-1 (British National Standard adoption ofthe above)

2- Within USA:

Various standards series have been issued such as:

 1. Underwriters Laboratory (UL96 & 96A),
2. The National Fire Protection Association (NFPA 780),
3. The Lightning Protection Institute (LPI-175).

Note:

For heavy fault conditions, Conductor Size should be calculated in accordance with IEEE
Std 80.

2- Material Requirements for Conductors and Air Terminations

 All lightning protection materials should conform to EN 50164-1 and

EN 50164-2 Lightning Protection Components requirements. The exceptions
to these requirements are non-current carrying devices such as down-
conductor fixings (clips), anti-vandal guards and mechanical supports.
 The IEC and EN standards prescribe the minimum material
requirements as summarized in the following Table:
 Table#1: Material Requirements for Conductors and Air
Terminations

Note:

 The standards do not prescribe any relative performance advantages

between these choices; all are adequate to conduct the lightning current.
But, when considering service life, aesthetics, galvanic compatibility with
building materials and ease of installation, there is generally a preferred
clear choice of material for a given structure.
 3- Comparison between Copper and Aluminum
as a Lightning Conductor Material

A conductor material should be chosen that is compatible with the surface it

is to be located upon and that which it is to connect to. As a typical
lightning protection system requires frequent bonds to nearby metallic
items, compatibility with this should also be assessed.

Comparison between Copper and Aluminum Conductor Materials is indicated

in the following table:

Aluminum Copper
lower cost More expensive than Aluminum

lighter weight More heavy than Aluminum

Less compatible with many building More compatible with many

materials building materials

Cannot be buried in the ground Can be buried in the ground

the aesthetics of eventual white the aesthetics of green verdigris of

corrosion of aluminum copper

Aluminum is prone to corrosion care should be taken in areas with

when in contact with limestone, sulphurous atmospheres (e.g. smoke
plaster, mortar and cement. For stacks), where stainless steel or
this reason, aluminum conductors lead covered copper may be more
should not be placed in direct appropriate
contact with such surfaces.Stand-
off fixings can be used (see below
figure), or PVC covered aluminum
conductors used
 Aluminum is prone to corrosion in
marine or sea-side environments

Aluminum should not be installed Copper should not be installed

where it will be exposed to water
run-off from copper (or copper
alloy) surfaces
above galvanized, zinc or aluminum
parts where water run-off occurs
(unless parts are protected such as
by PVC covering). Water run-off
from the copper surface carries fine
copper corrosion particles, which
when deposited on lower
galvanized, zinc or aluminum parts
may results in severe corrosion.

Aluminum should not be installed on

surfaces coated with alkaline based
paint.

Aluminum should not be installed in

locations subject to excessive
moisture (i.e. in gutters, or on
surfaces where water may be
retained).

Therefore, most lightning protection systems are entirely copper or utilize

an upper aluminum portion connecting to a copper earth termination
system. As aluminum and copper are not compatible, a bimetallic
joint should be used to interconnect these two materials.

Note:

As aluminum and copper are not compatible, a bimetallic joint should be used
to interconnect these two materials.

Bimetallic Connector
 4- Use of Dissimilar Metals

 Galvanic corrosion occurs when two dissimilar metals are in contact with each
other in the presence of an electrolyte. In this situation, one metal becomes the anode
and the other the cathode. The anode will tend to go into solution and therefore
corrode. The electrolyte can be water with impurities from the air, other surfaces or
from the metal itself
 The following Table shows the potential difference between dissimilar metals.
Combinations of metals with potential differences above 0.5 V should be rejected to
avoid excessive corrosion.
For example:

A bare copper conductor should not be directly connected to steel, as the

electrochemical potential difference is 0.53 V (≥ 0.5 V). However, if the copper is tin
plated then the difference becomes that of tin (0.24 V), which is acceptable.

 One method of reducing the effects of corrosion is to use plating of one or both
of the metals to reduce the electrochemical potential difference. Commonly, tin plated
copper conductors are used for this purpose. Tin plating also has the advantage of
stopping the appearance of green verdigris coating and reducing the chance of theft (as
the conductor no longer looks like copper). Tin plated copper should be used for
connections to:
 1. Lead,
2. Grey cast iron,
3. Steel (stainless steel connections do not need to be tinned),
4. Aluminum,
5. Cadmium.

The following Table shows the material of structure and its LPS compatible material:

5- Temperature Rise Criteria

In non-isolated lightning protection system, the down-conductors are primarily mounted

directly onto the structure (with no distance).
But, sometimes a separation distance is required between the down conductors and the
structure. This is governed by the criteria of temperature rise in the event of lightning
striking the lightning protection system.

Temperature Rise Criteria:

The temperature rise criterion is based on the level of flammability for the structure
walls; we have two cases as follows:

Case#1: If the wall is made of flame-resistant material or material with a normal

level of flammability

 In this case, the down-conductor systems may be installed directly on or in the

wall.
 For example, Wood with a bulk density greater than 400 kg/m2 and a thickness
greater than 2 mm is considered to have a normal level of flammability. Hence the
down-conductor system can be mounted on wooden poles.

Case#2: If the wall is made of highly flammable material

In this case, we have two sub-cases according to considering the temperature rise (when
lightning currents flow) is a hazard or not, this is can be known from table as follows:
 The below Table states the maximum temperature rise ΔT in K of the various
conductors for each class of lightning protection system. These values mean that,
generally, it is even permissible to install down conductors underneath heat insulation
because these temperature rises present no fire risk to the insulation materials. This
ensures that the fire retardation measure is also provided.
 So, the two sub-cases for case#2: If the wall is made of highly flammable
material, are:

Case#2-A: The temperature rise of the down-conductor systems is not hazardous

 In this case, the down conductors can be installed directly on the surface of the
wall.

Case#2-B: The temperature rise of the down-conductor systems presents a hazard

 In this case, the down conductors must be mounted (by using Standoff
brackets for example) to ensure that the separation distance between the down-
conductor and the wall is greater than 0.1 m. The mounting elements may touch the
wall.
 Standoff brackets

Notes:

 When installing the down-conductor system in or underneath heat insulation, the

temperature rise (on the surface) is reduced if an additional PVC sheath is used.
Aluminum wire sheathed in PVC can also be used.
 The erector of the structure must state whether the wall, where a down-
conductor is to be installed, is made of flammable material.
 6- Natural Components

 Natural conductive components can be used as an integral part of the lightning

protection system. Natural components are typically metallic structural items that will
not be modified during the life of the structure, such as reinforcing steel, metal
framework and roofing/cladding.
 Natural components must meet minimum material requirements which listed
in below Table and be electrically continuous with secure interconnections between
sections such as brazing, welding, clamping, seaming, screwing or bolts.

Table#2

 The above Table provides the thickness requirements for natural air terminations.
Where combustible materials are not present, and water ingress can be tolerated from a
puncture due to lightning, then thinner material is permitted for air-terminations. If the
materials do not meet these requirements, then they must be protected by the lightning
protection system.
 Metal pipes and tanks on roofs can be used, provided they meet the requirements
ofTables#1 and 2. Refer to the standard for requirements of tanks and piping that
contain combustible or explosive mixtures. It is not desirable to use vessels and pipe
work which contains gas or liquids under high pressure or flammable gas or liquids.
 The requirements for natural air-terminations differ from natural down-
conductors. Down-conductors and air-terminations need to withstand the ohmic heating
and electromechanical/magnetic forces, but air-terminations also need to withstand the
heat of the lightning plasma arc.
 The following parts of a structure can be used as “natural components” of the
lightning protection system:

1. Metal Installations
2. Facade Elements, Mounting Channels and the Metal Substructures of
Facades
3. Metal downpipes
4. Rebar in Reinforced Concrete
5. Rebar in Precast Concrete
6. Rebar in Prestressed Concrete
 Facade Elements as Down Conductors

For more information about using Natural Components as down conductors, please review
the Article " Conventional Lightning Protection System Components – Part Four ".

In the next Article, I will explain Step#4: Sizing of Air Termination System Components. Please, keep
following.
Design Calculations of Lightning Protection Systems – Part Sixteen
In Article " Design Calculations of Lightning Protection Systems – Part Two ", I indicated the lightning
protection design process involves a number of design steps as in Fig.1.

Fig.1: The Lightning Protection Design Process

Step#1: Characteristics of the Structure to Be Protected

Explained in Article " Design Calculations of Lightning Protection Systems –
Part Two "
 Step#2: Risk Assessment Study
Also, In above Article, I indicated that the risk assessment study can be done by (4) different methods
as follows:
Methods Of Calculations
For Risk Assessment
Study
First: Manual Method
(Equations And Tables
Method) as per IEC
62305-2
First: Manual Method
(Equations And Tables
Method) as per NFPA 780
Second: Software Method
For Performing The Risk
Assessment Study
Third: Excel Sheets
Method For Performing
The Risk Assessment
Study
Fourth: Online
Calculators Method Used
for Need for Lightning
Protection calculations
Step#3: Selection Of External LPS Type and Material
Articles
Design Calculations of Lightning Protection Systems –
Part Two
Design Calculations of Lightning Protection Systems –
Part Three
Design Calculations of Lightning Protection Systems –
Part Four
Design Calculations of Lightning Protection Systems –
Part Five
Design Calculations of Lightning Protection Systems –
Part Six
Design Calculations of Lightning Protection Systems –
Part Seven
Design Calculations of Lightning Protection Systems –
Part Eight
Design Calculations of Lightning Protection Systems –
Part Nine
Design Calculations of Lightning Protection Systems –
Part Ten
Design Calculations of Lightning Protection Systems –
Part Eleven
Design Calculations of Lightning Protection Systems –
Part Twelve
Design Calculations of Lightning Protection Systems –
Part thirteen
Design Calculations of Lightning Protection Systems –
Part Fourteen
 Explained in Article " Design Calculations of Lightning Protection Systems –
Part Fifteen "

Today, I will I will continue explaining other steps of Lightning Protection Design procedure.

For more information, please review the following Articles:

 Design Process for Lightning Protection Systems

 Design Calculations of Lightning Protection Systems – Part One

Step#4: Sizing of Air Termination System Components

1- Introduction

As we stated before in Article " Conventional Lightning Protection System Components – Part One " that:

Conventional Lightning Protection System LPS Components

The Conventional Lightning Protection System consists of two main parts (as in below
figure):
 External and Internal Lightning Protection System Parts

1- The External Lightning Protection System, which includes:

 Strike Termination Subsystem,

 Conductor Subsystem,
 Grounding Electrode Subsystem.

2- The Internal Lightning Protection System, which includes:

 Equipotential Bonding Subsystem,

 Surge Protection Subsystem.

Strike Termination Subsystem

Usually called “Air Termination Subsystem “, the purpose of the strike termination
subsystem is to intercept the lightning event and course it harmlessly into the conductor
subsystem. Thus it is vitally important to use a correctly designed air termination system.
When designing the external lightning protection system of a structure, we distinguish
between two types of air-termination system:

1. Non-isolated system,
2. Isolated system.

Isolated and Non-isolated Air Termination Subsystem

Also, The strike termination subsystem can take many forms specified by the various
engineering standards available, as follows:

strike termination subsystem Forms

 strike termination subsystem Forms according to
strike termination subsystem Type

A- Vertical Air Terminals,

B- Horizontal air termination network, which include two sub-forms:
1. Meshed conductor network,
2. Overhead wires (Catenary wires).

C- Combination of Vertical Air Terminals and Horizontal air termination network,

D- Natural Air Terminals.

For more information about Air Termination Subsystem, please review Article
" Conventional Lightning Protection System Components – Part One " mentioned in
above.
 2- Sizing of Air Terminals

First: Based on IEC 62305-3

Configurations and minimum cross-sectional areas of air-termination conductors, air

termination rods and down-conductors are given in below Table#1 and shall comply with
the requirements and tests according to the future IEC 62561 series.

Table#1
Notes to Table#1:
a
 Mechanical and electrical characteristics as well as corrosion resistance
properties shall meet the requirements of the future IEC 62561 series.
b
 50 mm2 (8 mm diameter) may be reduced to 25 mm2 in certain applications
where mechanical strength is not an essential requirement. Consideration should in this
case, be given to reducing the spacing between the fasteners.
c
 Applicable for air-termination rods and earth lead-in rods. For air-termination
rods where mechanical stress such as wind loading is not critical, a 9,5 mm diameter, 1
m long rod may be used.
d
 If thermal and mechanical considerations are important then these values should
be increased to 75 mm².

Second: Based on BS EN 62305-3

The BS EN 62305-3 standards prescribe the minimum material requirements as

summarized inTable#2. It should be noted that the standards do not prescribe any
relative performance advantages between these choices. All are adequate to conduct the
lightning current. When considering service life, aesthetics, galvanic compatibility with
building materials and ease of installation, there is generally a preferred clear choice of
material for a given structure.
 Table#2

Notes to Table#2:

 (1) 50 mm2 (8 mm diameter) may be reduced to 28 mm2 (6 mm diameter) where

mechanical strength is not an essential requirement,
 (2) For air-terminals of 1 m or less, 10 mm diameter may be used,
 (3) 50 mm2 with a minimum 2.5 mm thickness may be used with aluminum alloy,
 (4) Materials may be covered with PVC for aesthetic purposes.
 3- Sizing of Natural Air Terminals

The parts of a structure should be considered and may be used as natural air termination
components and part of an LPS, these parts are:

a) Metal sheets covering the structure to be protected provided that:

 The electrical continuity between the various parts is made durable (e.g. by
means of brazing, welding, crimping, seaming, screwing or bolting),
 The thickness of the metal sheet is not less than the value t’ given in Table#
3 (from IEC 62305-3) if it is not important to prevent puncture of the sheeting or to
consider ignition of any readily combustible materials underneath,
 The thickness of the metal sheet is not less than the value t given in Table# 3 if it
is necessary to take precautions against puncture or to consider hot spot problems,
 They are not clad with insulating material.

Table# 3

Notes:

 Where hot spot or ignition problems may arise, it should be verified that the
temperature rise of the inner surface at the point of strike does not constitute a danger.
Hot spot or ignition problems can be disregarded when the metal sheets lies inside an
LPZ0B or higher.
 A similar Table to Table#3 but as per BS EN 62305 is provided in below.

b) Metal components of roof construction (trusses, interconnected reinforcing steel,

etc.), underneath non-metallic roofing, provided that damage to this non-metallic
roofing is acceptable.

c) Metal parts such as ornamentation, railings, pipes, coverings of parapets, etc., with
cross sections not less than that specified for standard air-termination components.

d) Metal pipes and tanks on the roof, provided that they are constructed of material
with thicknesses and cross-sections in accordance with Table #1.

e) Metal pipes and tanks carrying readily-combustible or explosive mixtures, provided

that they are constructed of material with thickness not less than the appropriate value
of t given inTable#3 and that the temperature rise of the inner surface at the point of
strike does not constitute a danger.
Notes:

 If the conditions for thickness are not fulfilled, the pipes and tanks shall be
included into the structure to be protected.
 Piping carrying readily-combustible or explosive mixtures shall not be considered
as an air termination natural component if the gasket in the flange couplings is not
metallic or if the flange-sides are not otherwise properly bonded.
 A thin coating of protective paint or about 1 mm asphalt or 0,5 mm PVC is not
regarded as an insulator.
 It is not desirable to use vessels and pipe work which contains gas or liquids under
high pressure or flammable gas or liquids.
 Where combustible materials are not present, and water ingress can be tolerated
from a puncture due to lightning, then thinner material is permitted for air-terminations.

Don't forget that The requirements for natural air-terminations are:

 To withstand the ohmic heating and electromechanical/magnetic forces,
 To withstand the heat of the lightning plasma arc.

4- Positioning / Placement of Air Termination System Components

The three basic methods recommended for determining the position of the
air termination system components are:

1. The Rolling Sphere Method (RSM),

2. The Protective Angle Method (PAM),
3. The Mesh Method.

Any of these methods can be used to determine:

1. The optimum location of the air-termination System

Components,
2. The resulting down-conductor,
3. earthing requirements.

Notes:
 Different design methods can be applied to different regions of a
single lightning protection system, provided the zones afforded by each
method overlap to protect the entire structure. I.e. we can use the (3)
methods together in designing one complete LPS for given structure.
 Generally most of the standards consider the three methods as
equivalent, although there are limits on the application of the protection
angle and mesh methods as in below table:

The rolling sphere method is recommended as

the most universal and most effective method.
The rolling sphere method generally provides
the most optimized design and the vertical air-
terminal is far more effective at capturing
The Rolling Sphere
lightning flashes than mesh conductors
Method (RSM)
installed upon, or just above structure surface.
For example; Rod air-terminations of height in
the region of 0.5 m are preferable to shorter
rods or conductors on the building surface.

The Protection Angle The protection angle method can only be used
Method (PAM) with limited vertical distances (limited height).
The mesh method is more suitable for the
The Mesh Method protection of flat/plane surfaces.

Suitability Of Air-Termination Forms and Design Methods

Meshed conductors used as air-terminations should not be confused with the

mesh method. While the mesh method requires the use of surface mounted
meshed conductors (a grid) to protect flat surfaces, the rolling sphere and
protection angle method can also be used to determine protection provided
by elevated meshed conductors to protect a variety of compound surfaces.
The below Table shows the Suitability Of Air-Termination Forms and Design
Methods.

Protection Method
Air-Termination
Rolling Mesh Protection
Sphere Method Angle
Rod √√√ √√
Meshed conductors – (on
√(1)
structure surface)
Meshed conductors –
√√ √√
(elevated from structure)
Catenary wires √√ √√
 Note (1): Mesh method is appropriate for the evaluation of the protection
of the bound flat surface. Rolling sphere and protection angle methods
can be used to determine protection of adjacent areas.

The Class of LPS/LPL influences on the (3) Positioning Methods

According to IEC 62305-3, Based on the class of the lightning protection system, the below table
indicate Maximum values with each class for:

1. Rolling sphere radius,

2. Mesh size,
3. Protection angle permitted,

Class Of LPS
Rolling Sphere Radius
(Lightning Mesh Size (M) Protection Angle
(M)
Protection Level)
I 20 5x5
II 30 10 x 10 See below figure
III 45 15 x 15
IV 60 20 x 20
 Protection Angle with corresponding height and Class of LPS

Notes:

 h is the height of air–termination above the surface to be protected,

 The angle will not change for values of h below 2 m,
 Lightning protection class I, II, III & IV relate to protection level I, II, III, & IV respectively
as in below table:

Lightning protection
Class of LPS
level (LPL)
I I (highest protection)
II II
III III
IV IV (lowest protection)

For example if the risk assessment determines that a lightning protection system with lightning
protection class II is required to reduce the risk to below the tolerable level, then the design of
the lightning protection system will need to be in accordance with the requirements of lightning
protection level II (or higher). The greater the level of lightning protection (LPL I being the
greatest), the larger the resulting material requirement for the lightning protection system.

From the above Table and Figure, the following table can be used for Positioning of air
termination according to the level of protection

h (m) 20 30 45 60 Mesh Width d (m)

 Protection
R (m) α0 α0 α0 α0
level
I 20 25 * * * 5
II 30 35 25 * * 10
III 45 45 35 25 * 15
IV 60 55 45 35 25 20
* Rolling sphere and mesh methods only apply in these cases

And the parameters h, R and α are indicated in the below figure:

Positioning of air termination according to the level of protection

Where:

h is the height of air–termination above the surface to be protected,

R is the radius of the rolling sphere,
α is the protective angle of the conic space in degrees.