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Lightning Protection Marking and Application Guide

Lightning Protection

Marking and Application Guide

SECONDARY ROOF AREA

–

A secondary roof is less than 10 percent of the total roof area of the

protected building and lower than adjacent roofs.

STACK, HEAVY-DUTY

–

A smoke or vent stack more than 75 feet (22.9 m) high, and in which the

cross-sectional area of the flue is more than 500 square inches (0.3 m2).

STRIKE TERMINATION DEVICE

–

A metallic component of a lightning protection system that

intercepts lightning flashes and connects them to a path to ground.

STRIKING DISTANCE

–

The distance over which final breakdown of the initial strike to ground or

to a grounded object occurs.

SURGE PROTECTIVE DEVICE (SPD)

–

A device composed of at least one non-linear

component and intended for limiting surge voltages on equipment by diverting or limiting surge

current and is capable of repeating these functions as specified.

ZONE OF PROTECTION

–

The space adjacent to a grounded air terminal or mast or overhead

ground wire that is substantially immune to direct strokes of lightning.

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Lightning Protection Marking and Application Guide

2. STRUCTURE PROTECTION

Determining the correct methodology for designing a system of protection is critical to its

efficiency and functionality. An average size structure, with a simple roof type, one roof elevation,

no uneven vertical changes, and the protection techniques can be rather straightforward and easy

to design.

However, if the building structure becomes complex with changes in roof elevations such as a

multi-story section, defined shapes such as dormer projections, or tall objects such as stacks, it

will require different considerations for design to afford proper protection of the entire structure.

There are three basic methodologies for determining a protection design scheme. Each of the

methods listed below is important, and can be used to develop an effective basic design.

The protection schemes shown here are considered Class I; those are buildings less than 75 feet

in height.

For Class II structures (those exceeding 75 feet in height or structures such as stacks, steeples

etc.) the protection shall include those for Class I but with Class II Air Terminals, cable connectors

and splices shall be bolted or welded and rated Class II.

Cable and cable connectors for Class II shall be rated as such and conductor cable shall be rated

Class II and be continuous from air terminal to ground and interconnected with the balance of the

system.

a. Air Terminal Placement using the standard grid placement scheme.

When establishing a zone of protection the air terminal tip is located at not less than 10

inches above the protected object if the interval spacing is not more than 20 feet

between air terminals. If a 24-inch air terminal is used, the air terminal spacing may be

increased to 25 feet

When the roof exceeds 50 feet in length or width or both directions the spacing can be

increased up to 50 feet between terminals on flat or gently sloping roofs. Pending roof

design, air terminals may be permitted to be in a pattern not exceeding 50 feet apart in

the center part of the roof plan. The perimeter edge spacing can be up to 25 feet

between terminals when 24-inch air terminals are used.

When the roof is pitched with eaves height of 50 feet or less above grade and having

no structural projections such as roof dormers or other projections, it requires

protection only be mounted to the ridge of the projection roofline.

Air terminals can be mounted on the ridge at spacing not greater than 25 feet. If other

projections or are present such as a dormer, irregular roof lines or lower or higher

elevations that area may need air terminal placement based on its physical size and

shape. Air terminals 10 inches in height and spaced not greater than 20 feet apart are

permitted, interval spacing may be increased to 25 feet when 24-inch terminals are

installed.

The figures below (fig. 8.1 & 8.2) will illustrate the typical roof protection scheme for

most installations with flat roof structures that would be found on warehouse, strip

malls and many commercial office structures. Air terminal spacing can be either 20 or

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Lightning Protection Marking and Application Guide

Lightning Protection

Marking and Application Guide

25 feet pending on terminal height. Perimeter and down conductors, with connections

to ground rods are also shown.

A= 50 ft.

B= 150 ft.

C= 20 or 25 ft

pending air terminal

Height and not more

than 2 ft from roof

edge.

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Lightning Protection Marking and Application Guide

Rolling Sphere Design.

The rolling ball or more correctly the rolling sphere method uses an imaginary

spherical shaped ball with a 150-foot radius that rolls over the building structure

touching only the tips of the air terminals mounted on the roof. This dimension is based

on the fact that the lightning strike distance near the surface of the earth is about 150 ft.

or less. The sphere is tangent to earth and will contact three or more correctly spaced

air terminals when rolled over any portion of the roof structure.

When using this imaginary sphere and rolling up over and down the other side of the

building, it will only touch the roof mounted air terminals, never the building structural

roof surfaces. When using the spherical shape to determine the zone of protection for

the building structure all possible placements of the sphere on the structure shall be

considered for terminal placement.

A protected building that exceeds the height of the lower building structure will protect

the lower structure when it lies within the zone of protection of the rolling sphere.

Remember that the protective sphere has a 150 ft. radius or is really a 300 foot

diameter round ball.

A protected building that is more than a 150 feet high will provide protection for lower

elevation roof areas of adjacent, or connected structures, when the lower structure

A= 10 inches minimum height

B= 24 inches or more in height

C= support shall be located at

not less than one half the height

of the terminal

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Lightning Protection Marking and Application Guide

Lightning Protection

Marking and Application Guide

roof is protected by the arc of the sphere that is tangent to the side of the protected

building, and to the earth.

c. Protective angle

The protective angle method is not depicted diagrammatically in UL 96A but is based

on a ratio of upper building height and size to lower building area height and size with

location and placement of air terminals. These methods do not apply to structures over

50 ft. in height. Methods A, B should be utilized.

If not more than 25 feet to the lower eaves, a 2:1 ratio (2 horizontal feet of building

coverage for each vertical foot in elevation) can protect the lower portion of a building

or out to the first air terminal location on a large roof structure. If not more than 50 feet

to the eaves or to the perimeter air terminal location on a higher flat roof, the lower roof

is protected by the higher roof in a 1:1 ratio (1 foot horizontal coverage for each vertical

foot from the upper structure). This ratio would also cover the larger flat roof to the first

air terminal based on the height ratio. In the diagrams below you can see how this ratio

is applied.

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Lightning Protection Marking and Application Guide

Lightning Protection

Marking and Application Guide

Air Terminal

All components on upper

25 feet (7.6 m) shall be lead

covered copper or bronze,

stainless steel, or other

acceptable corrosion

resistant material

Straight splicer as

required

Bare cable, holder.

See material and spacing

requirements

Ground guard to protect

downlead from

mechanical damage

Connect to water service

if within 25 feet (7.6 m)

A = 8 feet (2.4 m) maximum

spacing of air terminals

Bond to rebar (concrete

encased steel bars) at

top and bottom of each

downlead of reinforced

concrete stacks

Bond to ladders, hoists

and the like at upper and

lower ends: bond

sections of ladder

together

Cross connect

downleads at midheight

on all stacks more than

200 feet (61 m) high

Bond to platforms

Bond to breeching

Ground Terminal

Cross connect downleads

underground

Heavy Duty Stacks

Lightning Protection Marking and Application Guide

3. Heavy-Duty Stacks

Stacks above 75ft in height require some special consideration in both design and material used

for the system. All components shall be Class II and class II modified. The components in the

upper 25 feet shall be copper, copper alloy, bronze or stainless steel. The top 25 feet can be a

high corrosion zone and extra protection of a min of 1/16 in coating of lead is required for

terminals, mounting brackets and conductors. Aluminum components are prohibited in this

installation.

Class II air terminals on stacks shall be solid copper, copper alloy, stainless steel, titanium or

monel metal. The installation shall be evenly distributed around the top of a round stack at

intervals not to exceed 8 feet. If the stack is square, the location shall be not more than 2 feet from

corners and spaced not more than 8 feet apart.

Each Class II air terminal shall be not less than 18 inches in height and not more than 30 inches in

height. The diameter shall be not less than 5/8 inch in diameter. All terminals shall be connected

together and there shall be at least 2 down conductors on opposite sides of the stack. Reinforcing

steel in concrete stacks shall be electrically continuous and shall be bonded to the lightning

protection system at its upper and lower ends at down-lead locations.

4. Components Selection

A protection system and its components are really simplistic when you step back and look at the

overall system. What is required is a means to catch a lightning strike at some point on the

structure, and then conduct it to an electrode buried in the earth so it can be dissipated.

Along the route to earth, terminals, conductors and grounding electrodes minimize damage to the

structure and contents within it. However simple as it may appear, there are some complexities

along the way. In accordance with NFPA 780 if an LPS component product is listed, labeled per

UL 96 than that product shall be selected and installed. The use of listed products gives greater

assurance that when correctly installed in accordance with 96A or NFPA 780 that the entire

lightning protection system can be “Site inspected” and receive the UL Master Label Certificate.

All components used in an LPS shall be of the following: copper, copper alloy, or electrical grade

aluminum unless otherwise specified in the UL 96A Standard. Copper components shall not be

installed on or in contact with surfaces of aluminum or external galvanized steel surfaces.

Any aluminum or aluminum alloy product shall not come into direct contact with earth, and any

bimetallic fitting shall not be installed within 18 inches above earth level. Aluminum products shall

not be embedded in concrete or masonry, in direct contact with a surface coated with alkaline

paint, installed in wet locations such as inside of eaves or downspouts.

Air Terminals: shall be not less than 10 inches long, less than 3/8-inch in diameter and may be

manufactured in separate parts if longer than 10 inches. The terminal shall be provided with an

integral base support, or shall have not less than five full threads of engagement with a separate

attachment base mounted to the structure. If the terminal has internal threads the wall thickness

shall be not less than 1/16 inch at the base of the threads. Ornaments or decorations are

permitted on air terminals, but shall not exceed 20 square inches in any plane. Air Terminals

longer than 24 inches shall have bracing at half its height and listed for the purpose

Base Supports: The air terminal bases are permitted to be stamped or cast construction. If

stamped, the thickness shall be 0.097 for aluminum and 0.061 for copper material. If cast either

copper or aluminum shall be at least 3/32 inches thick. A base support must incorporate a

Lightning Protection Marking and Application Guide

Lightning Protection

Marking and Application Guide

connector fitting for connection of the lightning conductor. The conductor contact area must be at

least 1-1/2 inches on all sides of the cable.

Air Terminal Braces: When air terminals exceed 24 inches in height, they shall be braced or

supported at least one-half of the terminal height in accordance with section 8.1.6 of UL 96A. The

brace shall be at least ¼ inch rod, constructed from aluminum, copper/copper alloy, stainless

steel, or hot dipped galvanized if made of steel and shall be flattened on the end for attachment to

the structure with at least a 10-24 bolt or screw.

Conductors: Lightning conductors do not fall into the basic wire size categories, as most field

electricians know them.

Class I- main conductors: Stranded copper conductors shall be at least 57,400 circular mils at

187 lbs per 1000 ft. Aluminum conductors shall be at least 98,600 cir.mils at 95 lbs per 1000 ft.

Secondary or bonding conductors the minimum size shall be 26,240 cir. mils for copper and

41,100 cir. mils for aluminum

Class II- main conductors; shall be not less than 115,000 cir. mils for copper conductor at 375 lbs

per 1000 ft and, 192,000 cir. mils. for aluminum conductors at 190 lbs per 1000 ft.

Secondary or bonding conductors the minimum size shall be 26,240 cir. mils for copper and

41,100 cir. mils for aluminum.

Grounding Electrodes: Air Terminals, main and secondary conductors plus all other ancillary

parts are for the sole purpose of conducting a lightning stroke to earth and dissipating it through

the use of various grounding electrode methods.

The grounding electrode shall be a rod of not less than ½ inch in diameter, and 8 feet in length and

be of copper-clad steel, solid copper, or stainless steel. The rod shall extend vertically not less

than 10 feet into the earth and below the frost line where possible.

Concrete encased shall only be used in new construction. It shall be the same diameter as the

main-size conductor. It shall be 20 feet in length and be encased in at least 2 inches of concrete.

Or Steel rebar shall also be permitted as a grounding electrode. At least 20 feet of (#4 or ½ in dia.)

steel reinforcing bar shall be used. Overlapping at least 20-rod diameters shall be maintained if

more than one piece is spliced in the footing, using tie wire or welding.

A main-sized conductor can also be buried from each down conductor in the form of a radial. A

radial conductor must be at least 12 feet in length and buried at least 18 in depth.

A ground ring shall be permitted if at least 18 inches under the earth and equal in size to the

main-size conductor.

Ground plate(s) shall be permitted if 2 sq. feet or more in size and 0.032 in thick or more and

buried not less than 18 inches under the soil.

Where there is shallow topsoil, a combination of the methods above shall be permitted to provide

an effective means for dissipating a lightning stroke.

Lightning Protection Marking and Application Guide

Common Grounding and Bonding: The lightning protection system grounding system shall be

bonded and connected to the grounding electrode system for the electrical service,

communication system ground, any antennae system grounds, as well as underground metallic

piping systems With main size lightning protection cable and connectors see exception in 10.4.2

for the utilization of ground in accordance with Articles 250, 620,800, and 810.

These systems shall include the water service, well casings located within 25 feet of the structure,

gas piping, underground conduits, underground liquefied petroleum gas piping etc.

The connection to any utility gas line shall be on the customer’s side of the meter. The bonding

conductor shall be sized the same as the main down conductor and main system conductor.

5. Basic Requirements for System Certification and the UL Master Label Certificate

Program

Once the system is completed, Underwriters Laboratories Field Staff can perform an on-site

inspection. The system inspection begins with an overall visual inspection for neat and

professional installation of the following but not limited to:



Air terminal layout and placement position with at least 2 directional paths to ground based

in structure elevation, roof style, and projections as specified within the Zone of Protection.



Air terminals tips shall be a minimum of 10 inches in height above the structure spaced not

more than 20 feet apart for perimeter protection



When terminals greater than 24 inches in height are used, they shall be supported at a

point at least half the height the rod and be spaced more than 20 but not less than 25 feet

apart for perimeter protection



Any object elevated above the normal roof height and with a surface thinner than 3/16 inch

shall be protected, i.e.: exhaust fan housings, camera masts, etc.



All lightning protection system components shall be listed, excepting hardware screws,

bolts etc.



Main size conductors shall be used for bonding other systems to include but not limited to:

metallic water systems, steam or hot water heating systems, electric services, telephone

systems, antenna grounds, other large grounded metallic masses and shall not be smaller

than 6 AWG.



The grounding terminal rod shall be at least 8 ft in length and not less than 1/2 in. dia.,

buried not less than 10 ft plates, concrete encased, rings and trenched systems are

permitted as well.



Copper components are not mounted on aluminum or external galvanized surfaces.



Cable bend radius at corners or over the building sidewall with 90 deg minimums 8 in

radiuses.



Attachment of cable secured to air terminals, and building shall be secured along the

cable run and attachments shall not be more than 3 ft apart.



Aluminum components shall not be installed in direct contact of copper roof material or

below any run off from copper surfaces.



Aluminum components shall not be in direct contact with earth

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