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Corrosion Prevention and Control (CPC)

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DAU GLOSSARY DEFINITION

Alternate Definition

Corrosion Prevention and Control (CPC) is the rigorous application of management principles, engineering design and analysis, quality assurance (QA), non-destructive inspection (NDI), manufacturing, operations, and support technologies and practices to prevent the start of corrosion, avoid functional impairment due to corrosion, and define processes for the tracking and repair of corrosion problems. Although not required as an element (e.g., Logistics, Test and Evaluation (T&E), Manpower, Personnel, and Training (MP&T) of DoD Risk Management (RM)), incorporating CPC as part of your RM is an effective way to provide tracking and mitigation of corrosion for the system/equipment.  

Also - 

The processes and techniques to prevent and control corrosion from affecting the availability, cost, and safety of military equipment safety.

General Information

The DoD acquires, operates, and maintains a vast array of physical assets, ranging from aircraft, ships, ground combat vehicles, and materiel, as well as wharves, buildings, and other infrastructure. These assets are subject to degradation due to corrosion. The impacts of corrosion are detailed below:

  • Safety - Multiple system mishaps have been attributed to the effects of corrosion.  For example, corrosion-related structural cracking has resulted in catastrophic failure and corroded electrical contacts have contributed to mishaps.
  • Availability - Systems are routinely unavailable due to corrosion deficiencies.
  • Cost - Approximately 20% of all systems maintenance is attributable to corrosion, costing DoD more than $19 billion annually.

General responsibility for Department of Defense CPC rests with the Under Secretary of Defense for Acquisition & Sustainment (USD (A&S)), which establishes policy, administers research and funding, and operates the Office of Corrosion Policy and Oversight (CPO).  The CPC Community of Practice brings together research engineers, scientists, maintainers and managers to collaborate.  

DoD Program Managers (PM) are required to identify and evaluate corrosion considerations throughout the acquisition and sustainment phases that reduce, control, or mitigate corrosion in sustainment.

The PM will perform corrosion prevention and control planning and include corrosion control management and design considerations for corrosion prevention and control in the System Engineering Plan (SEP) and Life Cycle Sustainment Plan (LCSP).  The PM also must ensure that corrosion control requirements are included in the design and verified as part of test and acceptance programs.

General DoD policy states that trade-off decisions during acquisition involving cost, useful service life, and effectiveness shall address corrosion prevention and mitigation and that CPC programs and preservation techniques must be implemented throughout the life cycle of all military equipment and infrastructure. DoD operates an overarching CPC IPT to implement strategies, determine objectives, and develop and execute plans, procedures, and roadmaps to reduce the overall impact of corrosion on DoD assets.  This aggressive approach is a result of Title 10 USC 2228  which implemented annual reporting by DoD and the Services, intended to engender a long term CPC strategy to include:

  • Expanded emphasis on corrosion prevention & mitigation
  • Uniformity of QA, testing and certification for new technologies
  • Collection and sharing of information relevant to the prevention of corrosion of military equipment and infrastructure.
  • Establishment of a coordinated Research and Development (R&D) corrosion mitigative program

The DoD CPC Planning Guidebook for Military Systems and Equipment was created to assist DoD and contractor program offices, PMs, and others working as part of IPTs to effectively manage corrosion during the entire acquisition process, including sustainment. The many tools and best practices in the guidebook can assist in reducing ownership costs and increasing system availability through improved CPC planning, and execution. The content of this guidebook was developed from broad and in-depth military and industry experience regarding the protection of systems/equipment from corrosion and its effects. The guidebook provides:

  • An overview of tools, techniques, and best practices for evaluating and implementing CPC in materials and processes
  • A discussion of material selection practices and finish treatments that positively impact the corrosion resistance of a system/equipment during all acquisition phases
  • Guidance on program management that can be implemented in organizations to address corrosion issues and develop CPC plans and that describes requirements and methods for:
    • Establishing and managing a Corrosion Prevention Team (CPT) (or equivalent functioning activity) that is appropriately integrated into all Integrated Product Teams (IPTs); and
    • Developing and implementing a Corrosion Prevention and Control Plan (CPCP).

The primary guiding directive on DoD CPC is the DoDI 5000.67 Prevention and Mitigation of Corrosion on DoD Military Equipment and Infrastructure. The policies and responsibilities described are applicable to all Services and DoD activities. An indication of how seriously CPC is regarded, and of its financial impact, the DoD is required to submit an annual report to Congress on CPC funding requirements, CPC issues and achievements and ROI. Each of the Services has established a Corrosion Control and Prevention Executive (CCPE), as the Department’s thought leader for corrosion issues. These billets are responsible for ensuring corrosion control and prevention are a part of system acquisition and sustainment, prioritization of related R&D studies and technological initiative and analyses, and consolidation and dissemination of lessons learned and best practices, between government, industry and academia, in the same sort of joint cooperative approach that has been successful in combatting Diminishing Manufacturing Sources and Material Shortages (DMSMS).  

For additional information, please visit the CPC DAU Community of Practice.