DoD Policy for Corrosion Prevention and Control (CPC)

1. DoD Policy for Corrosion Prevention and Control (CPC) CDR Larry Haukenes Professor of Engineering Management Defense Acquisition University

2. Purpose • Provide guidance on how to set up a Corrosion Prevention and Control Program • Suggest a corrosion prevention and control management structure • Provide points of contact and website for technical advice and counsel for corrosion issues

3. Outline • Corrosion Background • DoD New Directions • Corrosion Prevention and Control Planning • Corrosion Prevention and Control Planning Guide Book • Additional Information • Summary

4. Introduction • Coordinated, overarching, and integrated effort to address corrosion • National Defense Authorization Act 2003 • DoD emphasis impacts designers, program managers, maintainers, contractors, logisticians, contract personnel, manufacturing and production personnel, quality and research personnel

5. Background • Corrosion • Multi-BILLION dollar annual bill to DoD • Readiness and availability driver for DoD systems • Significant man-hour drain on personnel • Effects exacerbated by the longer life times of our systems and facilities Whether a weapon system, a facility or infrastructure: – it is affected!

6. Background • Congressional Interest and Mandate • Congress acts to require DoD to reduce corrosion costs • FY03 Defense Appropriation directs DoD to take action • DoD directed to designate an official responsible for prevention and mitigation of corrosion • DoD directed to report to congress • GAO directed to audit effort • DoD directed to develop strategy

7. Background • DoD Response • Designated DoD Corrosion Executive - PDUSD (AT&L) • Corrosion Task Force stood-up • Corrosion Strategy Developed • Direction to Service Secretaries • Corrosion Strategic plan delivered to Congress in November 2003 • Corrosion Prevention and Control Guide Book published in December 2003

8. New Direction • DoD Strategy To Reduce Corrosion Effects • Revised Policy and Regulations to emphasize corrosion • DoD5000 Series (5000.1 Directive and DoD 5000 Guidebook) • Corrosions Issues to be addressed at DAB • IIPT reviews for OIPT/DAB programs • Require CPC Planning • Increase support for standards and product qualification • Establish a Corrosion Information Exchange • Accelerate equipment modernization • Close marginal facilities CPC KEY ELEMENT OF ACQUISITON

9. CPC Planning • Corrosion Prevention and Control key consideration in designing, procuring and maintaining a DOD system • CPC Planning consists of two aspects: • Management structure • Technical and design requirements • Acquisition should treat corrosion as a performance parameter • Establish performance parameters via ICD/CDD/CPD • Program managers translate performance parameters into a Request For Proposal / Performance Specification • Contractors required to address CPC Planning Implementation methods and procedures will vary by the system but corrosion prevention and control must be addressed!

10. CPC Planning • Corrosion management structure and basics • Gov PM sets up Corrosion Prevention Advisory Team (CPAT) • Develop Corrosion Prevention and Control Plan (CPCP) • RFP evaluation factor for contractor CPCP • Gov and Cont establish technical design guidelines for life of system • How the particular program will implement CPC • Process / finish specification or equivalent document • Verification plan at system, assembly and component level • Corrosion technical manuals & maintenance concepts • Issues • Acquisition cost to implement changes • Warranties difficult to track and enforce • Priority of Corrosion Control versus other performance parameters

11. CPC Planning • CPC Plan • Guides initial development of performance specification / RFP • CPC Planning activity iterative through life of contract • Large number of corrosion variables • Large number of potential corrosion solutions • CPC Planning emphasized during design to minimizes deterioration of individual parts and assemblies, as well as entire system • Develop Metrics to assess effects of corrosion • Ensure timely evaluation and utilization of corrosion effects during testing

12. Corrosion Prevention and Control Planning Guidebook • PURPOSE • Provides guidance for materials, processes, techniques, and tasks to integrate into an effective corrosion prevention and control program • Methods to minimize the impact of corrosion on life cycle cost, readiness, reliability, supportability, safety and structural integrity • Living document available on-line to keep up with technical issues

13. Corrosion Prevention and Control Planning Guidebook • Intended Use • Describes development and implementation of the Corrosion Prevention Control Plan (CPCP) • Guide in establishing Corrosion Prevention Advisory Team (CPAT)

14. Corrosion Prevention and Control Planning Guidebook • Applicability • All DoD procuring activities and their respective contractors involved in the design, procurement, and upgrades of DoD Systems • Establishes guidance for Corrosion Prevention and Control Planning for all programs

15. Corrosion Prevention and Control Planning Guidebook • Program Management • Prepare a Corrosion Prevention and Control Plan (CPCP) • Define CPC requirements • List applicable specifications and standards • Address facility/system definition, design, engineering development, production / construction and sustainment phases • Corrosion Prevention Advisory Team (CPAT) • Established by Program Manager as early possible in a program or before program initiation • Membership • Chaired by designated representative of procuring agency • Includes specialists from procuring agency • Includes representatives from the development contractor • Duties • Guide and document overall CPC planning efforts • Interface with the Contractor’s Corrosion Team (CCT) • Guides design, manufacture, test and support of the system • Contractor Corrosion Team (CCT) • Membership (includes CPAT member) • CCT Duties

16. Corrosion Prevention and Control Planning Guidebook • Precautionary Design Measures • Material Selection • Avoid materials unsuitable to operational environment if possible • Consider material compatibility • Isolate dissimilar materials from each other • Protective Coatings • Use to isolate vulnerable materials from the environment • Design Geometries • Avoid crevices when possible • Avoid design features that make it difficult for protective coatings to function (sharp corners, for instance) • Avoid geometries that unnecessarily trap contaminants/moisture • Modify the Environment • Consider a design which allows for the modification of the environment to which materials will be exposed • Dehumidification and sheltering can be effective to modify the environment Design to eliminate corrosive contaminants or mitigate effects if exposed to contaminants!

17. Corrosion Prevention and Control Planning Guidebook • Documentation • Corrosion Prevention and Control to be addressed in Program Documentation: • Initial Capabilities Document (ICD) • Validated/Approved prior to Milestone A Meeting • Capability Development Document (CDD) • Validated /Approved prior to Milestone B Meeting • Capability Production Document (CPD) • Validated/Approved prior to Milestone C Meeting • Acquisition Strategy (ASR) • Request For Proposal (RFP) • Performance Specification • Contract • Corrosion Prevention and Control Plan (CPCP) • Process / Finish Specification • System Verification Plan • Corrosion Technical Manual Guidance • Maintenance Concept Definition and Specifics

18. Corrosion Prevention and Control Planning Guidebook • Documentation • Examples for ICD, CDD, CPD Text • Existing systems have been unable to meet required maintenance periodicity as a result of corrosion; • Corrosion occurring on existing systems places a large cost and labor-hour burden on the maintenance infrastructure; • Excessive corrosion on existing systems has resulted in reduced readiness. • The system maintenance should be performed in compliance with Environmental Protection Agency guidelines in effect at the time of the procurement and with minimal use and generation of hazardous materials or ozone-depleting chemicals. • The system should be resistant to the corrosive effects of a severe (add appropriate environment, such as air, marine, desert, seawater splash and spray, and occasional seawater immersion during operation, transport, and storage, etc.) atmospheric environment.

19. Additional Information Documents relevant to Corrosion Prevention and Control from government, industry and other non-government, and standards organizations, as well as Service Point of Contact information and CPCP Guide are available on the DOD Corrosion Exchange website: www.dodcorrosionexchange.org

20. Summary • Corrosion is a significant problem for DOD • Program Managers must take active role in defining, implementing, and executing a disciplined approach in Corrosion Prevention and Control Planning • Many resources to call upon when developing and executing a CPC Program

21. Corrosion Prevention and Control Program Training • DoD activities should request on-site CPC Program training from the Defense Acquisition University (DAU). • Contact following at DAU to schedule CPC Program training: • Capital & Northeast Region: (703) 805-2877 • Mid-Atlantic Region: (240) 895-7344 • South Region: (256) 722-1100 (DSN 788) • Mid-West Region: (937) 781-1025 • West Region: (619) 524-4800 (DSN 524) • Questions about the CPC Program, or CPC Program training may be addressed to: cpcprogramtraining@dau.mil

22. DoD Points of Contact Mr. Daniel J. Dunmire Director Corrosion Policy and Oversight Office of the Under Secretary of Defense (AT&L) (703) 681-3464 daniel.dunmire@osd.mil COL Larry Lee Deputy Director Corrosion Policy and Oversight Office of the Under Secretary of Defense (AT&L) (703) 695-0472 larry.lee@osd.mil