Corrosion Prevention and Control

Overview

The corrosion of military equipment and facilities costs the DoD over $20 billion annually. In addition, corrosion degrades system availability, safety, and Environment, Safety and Occupational Health (ESOH) factors. Therefore, acquisition officials should fully consider corrosion prevention and mitigation as early as possible in the acquisition life cycle (even prior to Milestone A) and implement appropriate strategies to minimize the life-cycle impact.

Planning

Sound Corrosion Prevention and Control (CPC) planning reduces life-cycle costs, improves maintainability and availability, and enhances ESOH compliance. The DoD Corrosion Prevention and Control Planning Guidebook for Military Systems and Equipment (MS&E) (i.e., CPC Planning Guidebook) helps Program Managers (PMs), Systems Engineers, Product Support Managers and other program staff develop and execute a comprehensive CPC approach.

DoDI 5000.85, DoDI 5000.67 and DoDD 4151.18 require CPC planning and execution for all acquisition programs across the life cycle. In accordance with DoDI 5000.88, Section 3.7.c, the PM is responsible for identifying and evaluating corrosion considerations throughout the acquisition and sustainment phases to reduce, control or mitigate corrosion. The PM, Systems Engineer and Product Support Manager should conduct CPC planning, ensure corrosion control requirements are included in the system design and verified as part of test and acceptance programs, and include CPC management and design considerations in the Systems Engineering Plan (SEP) and Life-Cycle Sustainment Plan (LCSP). DoDI 5000.91, Section 4.11.c further integrates CPC planning into sustainment. Product support planning should mitigate the appropriate CPC risks inherent in the system design to meet sustainment requirements.

Activities

Good CPC planning and execution includes, but is not limited to, the following elements:

Engaging corrosion expertise relevant to the system and its operating environment throughout the life cycle.
Examining legacy systems for possible corrosion-design improvements.
Documenting alternative material and process assessments that offer increased corrosion protection.
Including CPC as a consideration in trade studies involving cost, useful service life and effectiveness.
Incorporating CPC requirements, plans, specification, standards and criteria into relevant contractual documentation for all equipment and facilities.
Including CPC in integrated product support element (IPSE) development and evaluation, to include facilities (see Test and Evaluation Enterprise Guidebook (forthcoming)).
Identifying planning, resourcing, and acquisition of corrosion-related features for longevity, lowest total ownership cost (TOC) and sustained system effectiveness.
Retaining access to CPC resources throughout the life cycle.
Managing CPC risks.
Determining the corrosion severity of the operational environment.

All designated Acquisition Category (ACAT) programs are required to conduct CPC planning across their life cycle.

Documentation

In addition to the SEP and LCSP, CPC planning and execution for all ACAT programs should be reflected in other program documents, including, but not limited to:

Acquisition Strategy (AS)
Test and Evaluation Master Plan (TEMP)
Request for Proposal (RFP) and contract
Program schedule -- Integrated Master Plan/Integrated Master Schedule (IMP/IMS)
Funding/budget
Programmatic ESOH Evaluation (i.e., DFARS (Subpart 223.73, Minimizing the Use of Hexavalent Chromium))
System finish/process specification (add to the Statement of Work (SOW) and as a Data Item Description (DID) to the Contract Data Requirements List (CDRL))
Contractor Corrosion Prevention and Control Plan (add to the SOW/Statement of Objectives (SOO)/ Performance Work Statement (PWS) and as a DID to the CDRL)
System performance specifications

In the contract and RFP, CPC planning and execution should be addressed in the management and technical content of each contract/RFP section and subsection, including, but not limited to, the SOW, IMP/IMS, CDRL, DID, and system performance specifications (see System Engineering Guidebook, Section 2.5 Systems Engineering Role in Contracting, and the DoD Corrosion Prevention and Control Planning Guidebook for MS&E).

Products and Tasks

Product	Tasks
10-5-1: Developed corrosion prevention and control measure	Identify requirements for corrosion prevention and control for the acquisition in accordance with current guidance. Develop corrosion prevention and control measures and incorporate in acquisition plans. Secure corrosion prevention and control expertise Incorporate CPC requirements into system and product qualification requirements
10-5-2: Document corrosion prevention and control in program documentation	Identify requirements for corrosion prevention and control in accordance with current guidance. Identify system operational use requirements and related design features impacted by and having an impact on corrosion prevention and control as a result of the intended operational environment. Develop system performance specification design requirements in accordance with the corrosion prevention and control measures and identified corrosion prevention and control impacts. Define verification requirements, including the types and levels of corrosion. Develop the environmental test and verification plan. In coordination with system logisticians, incorporate corrosion prevention and control supportability measures into the life cycle sustainment plan (LCSP). Document CPC planning, including program technical requirements, engineering resources, technical risks and performance measures, technical structure and organization, as well as design considerations into the SEP. Document corrosion prevention and control compliance in program documentation.

Product

Tasks

10-5-1: Developed corrosion prevention and control measure

Identify requirements for corrosion prevention and control for the acquisition in accordance with current guidance.
Develop corrosion prevention and control measures and incorporate in acquisition plans.
Secure corrosion prevention and control expertise
Incorporate CPC requirements into system and product qualification requirements

10-5-2: Document corrosion prevention and control in program documentation

Identify requirements for corrosion prevention and control in accordance with current guidance.
Identify system operational use requirements and related design features impacted by and having an impact on corrosion prevention and control as a result of the intended operational environment.
Develop system performance specification design requirements in accordance with the corrosion prevention and control measures and identified corrosion prevention and control impacts.
Define verification requirements, including the types and levels of corrosion.
Develop the environmental test and verification plan.
In coordination with system logisticians, incorporate corrosion prevention and control supportability measures into the life cycle sustainment plan (LCSP).
Document CPC planning, including program technical requirements, engineering resources, technical risks and performance measures, technical structure and organization, as well as design considerations into the SEP.
Document corrosion prevention and control compliance in program documentation.

Source: AWQI eWorkbook