Table Of ContentCORROSION PREVENTION AND CONTROL
PLANNING GUIDEBOOK
SPIRAL 3
September 2007
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Introduction
I.1 Purpose
This document provides program and project managers with guidance for developing and im-
plementing a corrosion prevention and control program for DoD weapon systems and infrastruc-
ture. It includes corrosion-related policy; management planning; and technical and design
considerations that should be addressed for a viable design. This guidance is in accordance with
the DoD Corrosion Prevention and Control policy letter, signed by the Acting Under Secretary
of Defense for Acquisition, Technology, and Logistics (USD[AT&L]), 12 November 2003 (see
Attachment 1), and the Facility Corrosion Prevention and Control memorandum, signed by the
Deputy Under Secretary of Defense for Installations and Environment, 10 March 2005 (Appen-
dix F to Volume III).
Program and project managers—perhaps more than any other group—greatly influence DoD’s
corrosion-related cost, safety, and reliability impacts during the acquisition of systems and infra-
structure. That is why Volumes I and III of the Corrosion Prevention and Control Planning
Guidebook are targeted to them. The volumes identify the materials, processes, techniques, and
tasks required to develop and integrate an effective corrosion prevention and control program
during all phases of DoD weapon system and infrastructure development. The objective is to
minimize the effects of corrosion on life-cycle costs, readiness, reliability, supportability, safety,
and structural integrity.
Volume II of this guidebook focuses on equipment sustainment and includes information on life-
cycle logistics and the development of sustainment corrosion programs for weapon systems.
Following the guidance in this document in conjunction with applicable program and technical
documentation will result in the best possible balance between acquisition and life-cycle costs
for DoD systems.
I.2 Requirement
10 U.S.C. 2228 requires DoD to develop and implement a long-term strategy to address the corrosion
of its equipment and infrastructure. A key element of this strategy is programmatic and technical
guidance provided in this guidebook. Spiral 3 adds a volume on sustainment and refines the previous
acquisition guidance based on corrosion surveys, lessons-learned from program office reviews, and
Government Accountability Office audits. For example, GAO-07-618 evaluated the extent to which
DoD has incorporated corrosion prevention planning in weapon system acquisition. It should be
noted that corrosion prevention and control (CPC) planning is now required for all acquisition pro-
grams requiring an acquisition plan in the Defense Federal Acquisition Regulation Supplement
(DFARS). While sustainment has been included since the inception of the congressionally directed
OSD Corrosion Program, it has not been the focus of the program nor has it been separately ad-
dressed in the Corrosion Prevention and Control Planning Guidebook—until now.
Spiral Number 3 iii
The importance of both acquisition and sustainment is depicted in the graphic below. Sixty-
five to 80 percent of a system’s life-cycle costs occur in the sustainment phase. However, most
of the decisions (e.g., materiel selection, component reliability, designed maintainability) are de-
termined during the acquisition phase.
Figure 1. Acquisition and Sustainment Phases
I.3 Background
The Department of Defense acquires, operates, and maintains a vast array of physical assets,
ranging from aircraft, ships, ground combat vehicles, and other materiel to wharves, buildings,
and other infrastructure. These assets are subject to degradation due to corrosion, with specific
effects in the following areas:
• Safety. A number of weapon system and infrastructure mishaps have been attributed to
the effects of corrosion. For example, corroded electrical contacts on F-16s caused “un-
commanded” fuel valve closures (with subsequent loss of aircraft), and corrosion-related
cracking of F/A-18 landing gears resulted in failures (collapses) during carrier operations.
• Readiness. Weapon systems and infrastructure support activities are routinely out of
commission due to corrosion deficiencies. For example, corrosion has been identified
as the reason for more than 50 percent of the maintenance needed on KC-135 aircraft.
Also, corrosion of a fuel pipeline resulted in a leak of hazardous petroleum, oil, and lubri-
cants (POL) material into the environment endangering area water aquifers. Until it was
repaired, the loss of the pipeline also affected the ability to transfer fuel, hampering the
ability to perform the mission, detrimentally affecting readiness.
• Financial. The cost of corrosion to the DoD is estimated to be between $10 billion
and $20 billion annually.1
1 United States General Accounting Office, Opportunities to Reduce Corrosion Costs and Increase Readiness,
GAO-03-753, July 2003, p. 3.
iv Spiral Number 3
Introduction
DoD has a long history of corrosion prevention and control. The Department has been a leader in
many areas of research (ranging from understanding the fundamentals of corrosion to applying
advanced materials, coatings, inhibitors, and cathodic protection for corrosion control); however,
it also has very special corrosion-related challenges:
• DoD’s assets are getting older in both relative and absolute terms. The current ex-
pected—although often not planned—service lives of some aircraft, missiles, ships,
and infrastructure are much longer than any comparable commercial assets.
• In order to perform its mission, the Department must train, fight, and sustain infra-
structure in all environments, some of which are among the most corrosively aggres-
sive on Earth.
• DoD has unique corrosion-related issues. For example, many coatings used on vehi-
cles and other assets are formulated to perform a special function, such as resistance
to chemical agents or maintaining low signature. Corrosion is, at best, a secondary
consideration.
Corrosion costs DoD an estimated $10 billion–$20 billion annually. In an attempt to minimize
these costs, Congress enacted 10 U.S.C. 2228, which emphasizes DoD management and techni-
cal awareness of corrosion prevention and control. Corrosion is a long-term issue that usually
affects system operation some time after the system is procured; but the best time to combat
the effects of corrosion is early in system development.
According to DoD Directive 5000.1, The Defense Acquisition System, corrosion prevention,
control, and mitigation will be considered during life-cycle cost tradeoffs. Consideration of op-
erational and logistics capabilities (such as readiness, reliability, sustainability, and safety) is
critical to ensure the effectiveness of a weapon system, and is usually accomplished during con-
ceptual design, when the effects of corrosion on these capabilities should be addressed as well.
Corrosion is often “out of sight” and, therefore, “out of mind” until a failure occurs; and there is
a false perception that corrosion prevention and mitigation can be reverse-engineered later in a
system’s operational life cycle. The fact is, corrosion can have a significant impact on opera-
tional readiness and safety (both by itself and in conjunction with other damage phenomena), and
its interactions with these factors should be considered during the conceptual design phase.
National priorities dictate the need for extended service lives for DoD systems and infrastructure.
History indicates the effects of corrosion increase with system age, which only amplifies the
need to consider corrosion prevention as a primary design parameter. As a consequence, the
original designs of weapon systems should include the best materials and manufacturing proc-
esses. The only way to ensure an effective, across-the-board response to prevention or a dramatic
reduction of corrosion and its effects is to establish a standard DoD corrosion control philosophy
and methodology. With a clearly defined methodology, acquisition program managers and infra-
structure project managers can initiate and execute plans and actions to employ satisfactory materials
and processes.
Spiral Number 3 v
I.4 Document Structure
This guidebook is structured into three volumes—Equipment Acquisition; Equipment Sustain-
ment; and Facilities Acquisition/Sustainment—as outlined below.
• Volume I, Equipment Acquisition
(cid:131) Chapter 1, General Acquisition Program Management
(cid:131) Chapter 2, Program Management Corrosion Prevention and Control Planning
(cid:131) Chapter 3, Technical and Design Considerations
(cid:131) Appendix A, DoD Acquisition Process
(cid:131) Appendix B, Example of Charter for Corrosion Prevention Action Team
(cid:131) Appendix C, Example for Corrosion Prevention and Control Plan for Systems
and Equipment
(cid:131) Appendix D, Aerospace Systems Guidelines
(cid:131) Appendix E, Navy Ships and Submarines Guidelines
(cid:131) Appendix F, FAQs about Corrosion Prevention and Control Planning
• Volume II, Equipment Sustainment
(cid:131) Chapter 1, Life-Cycle Logistics
(cid:131) Chapter 2, Corrosion Programs for Weapon System Sustainment
(cid:131) Appendix A, Equipment Cost-of-Corrosion Baseline Studies
• Volume III, Infrastructure
(cid:131) Chapter 1, General Project Management Requirements
(cid:131) Chapter 2, Project Management Corrosion Prevention and Control Planning
(cid:131) Chapter 3, Technical and Design Considerations
(cid:131) Appendix A, DoD Construction Process
(cid:131) Appendix B, Example of Charter for Corrosion Prevention Advisory Team
(cid:131) Appendix C, Example of Corrosion Prevention and Control Plan for Facilities
(cid:131) Appendix D, Facilities and Infrastructure Design Guidance
(cid:131) Appendix E, Facilities Cost of Corrosion Results
(cid:131) Appendix F, Facility Corrosion Prevention and Control Memorandum
• Attachments (to all volumes)
(cid:131) Attachment 1, Corrosion Prevention and Control Memorandum
(cid:131) Attachment 2, Acronyms
(cid:131) Attachment 3, Principal Integrated Logistics Support Element Definitions
(cid:131) Attachment 4, Corrosion Points of Contact—Organization and Personnel
(cid:131) Attachment 5, CPC Policy, Regulations, and Directives
(cid:131) Attachment 6, Scales, Tables, and Elements
vi Spiral Number 3
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Volume I Equipment Acquisition
Table of Contents
1. General Acquisition Program Management Requirements.........................1-1
1.1 Introduction................................................................................................................1-1
1.1.1 Intended Use........................................................................................................1-2
1.1.2 Applicability........................................................................................................1-2
1.1.3 Policy/Guidance...................................................................................................1-2
1.1.4 Applicable Documents.........................................................................................1-3
1.1.5 Definitions............................................................................................................1-3
1.2 General Program Management Requirements...........................................................1-4
1.2.1 Systems Acquisition Community........................................................................1-4
1.2.2 System Verification Plan in Acquisition..............................................................1-6
2. Program Management Corrosion Prevention and Control Planning...........2-1
2.1 DoD Corrosion Performance Specification Issues....................................................2-1
2.2 Management Planning...............................................................................................2-2
2.2.1 CPC Planning.......................................................................................................2-2
2.2.2 Programmatic Considerations..............................................................................2-3
2.2.3 Corrosion Prevention and Control Planning........................................................2-4
2.2.4 Corrosion Prevention and Control Plan...............................................................2-8
2.3 Integrated Logistics Support as It Applies to the CPC Program...............................2-9
2.3.1 ILS Policy............................................................................................................2-9
2.3.2 ILS Elements........................................................................................................2-9
3. Technical and Design Considerations.........................................................3-1
3.1 Technical Considerations...........................................................................................3-2
3.1.1 Variables Influencing Corrosion..........................................................................3-2
3.1.2 Potential Solutions to Corrosion Problems..........................................................3-2
3.1.3 Assessments of Corrosion Impacts in Acquisition..............................................3-2
3.1.4 Accelerated Corrosion Tests in Acquisition........................................................3-3
3.1.5 Service Laboratories............................................................................................3-4
Spiral Number 3 vii Volume I
3.2 Design Considerations...............................................................................................3-4
3.2.1 Material Selection................................................................................................3-4
3.2.2 Protective Coatings..............................................................................................3-4
3.2.3 Design Geometries...............................................................................................3-4
3.2.4 Environmental Modifications..............................................................................3-5
3.2.5 Process/Finish Specification or Equivalent Document in Acquisition................3-5
Appendix A DoD Acquisition Process
Appendix B Example of Charter for Corrosion Prevention Action Team
Appendix C Example of Corrosion Prevention and Control Plan
for Systems and Equipment
Appendix D Aerospace Systems Guidelines
Appendix E Navy Ships and Submarines Guidelines
Appendix F Frequently Asked Questions about Corrosion Prevention
and Control Planning
Figures
Figure 1-1. Volume I Organization..............................................................................................1-1
Figure 1-2. Defense Acquisition Process.....................................................................................1-5
Figure 2-1. Defense Acquisition Process.....................................................................................2-2
Volume I viii Spiral Number 3
1. General Acquisition Program Management
Requirements
It is simply good sense and good management to prevent corrosion through better de-
sign and selection of materials, and to reduce treatment costs by detecting corrosion
earlier and more precisely. Fighting corrosion is just one of the things that we need to
constantly do so that we are always ready to perform the fundamental mission of the
Department, which is to maintain our national security.1
—DoD Corrosion Executive
1.1 Introduction
Program managers—perhaps more than any other Figure 1-1. Volume I Organization
group—greatly influence DoD’s corrosion-related
costs, safety, and reliability issues, regardless of
whether it is in the acquisition of new systems or General
Program
during the sustainment of existing systems. That is Management
Requirements
why this volume of the Corrosion Prevention and
Control Planning Guidebook is targeted to them. It
DoD 5000 Systems Acquisition
identifies the materials, processes, techniques, and
•Concept Refinement
tasks required to integrate an effective corrosion pre-
•Technology Development
vention and control program during all phases of
•Systems Development & Demo
DoD weapon system and infrastructure development •Production & Development
•Operations & Support
and sustainment. The objective is to minimize the
effects of corrosion on life-cycle costs, readiness,
reliability, supportability, safety, and structural integ- PM CPC
Planning
rity. Following the guidance in this document in con-
junction with applicable program and technical
documentation will result in the best possible bal-
ance between acquisition and life-cycle costs for
DoD systems.
Management Technical and
Planning and ILS Design Corrosion
Figure 1-1 outlines the structure of Volume I of this Considerations
guidebook. The remainder of this chapter further ex- •Management Planning
•Technical Considerations
-Programmatic Considerations
plores the acquisition-related corrosion requirements as -Corrosion variables
-CPC Planning -Potential solutions
they relate to program management. It also identifies -CPAT -Impacts
general program manager requirements. Chapter 2 out- -CCT -Testing
-CPCP -Service laboratories
lines specific corrosion-related planning requirements.
•ILS Planning •Design Considerations
Chapter 3 focuses on technical and design considera- -Material selection
-Coating
tions that may impede or eliminate corrosion.
-Design geometries
-Environment
-Process/finish specifications
1 AMMTIAC Quarterly, Volume 7, Number 4, Winter 2003, p. 9.
Spiral Number 3 1-1 Volume I
