Corrosion Prevention and Control Planning Guidebook for Military Systems and Equipment

Overview

The Department of Defense (DoD) recognizes the criticality of corrosion prevention and control (CPC) planning to acquisition program success:

• It Is Law — Title 10 U.S.C. § 2228 mandates that CPC planning must be part of the 10 U.S.C. § 4252 certification.
• It Is Policy — CPC planning is required in various policy documents, including, but not limited to, DoD Directive 5000.01, in conjunction with DoD Instruction (DoDI) 5000.67, DoDI 5000.88, and DoDI 5000.91.
• It Is Costly — DoD spends approximately $20 billion annually goes on maintenance due to corrosion, almost 20% of every maintenance dollar. Corrosion also significantly affects the availability and safety of systems and equipment.

Corrosion is not simply a sustainment concern; it needs to be addressed from system inception to disposal (i.e., cradle to grave). CPC at the early stages in a system development reduces the Total Ownership Cost and improves availability and safety. 

According to Title 10 U.S.C. § 2228, "corrosion is the deterioration of a material or its properties due to a reaction of that material with its chemical environment." Corrosion is far more widespread and detrimental than merely rust of steel or iron. The acquisition program needs to consider additional materials, including other metals, polymers, composites, and ceramics affected by the operational environment. 

This guidebook assists the acquisition and sustainment workforce, and system procuring activities in developing and executing an effective CPC plan. It focuses on these keys to CPC success: 

• Integrate CPC planning and execution early and throughout the acquisition process.
• Resource the necessary funding and expertise.
• Manage CPC risks.
• Incorporate CPC language in procurement and contract documents.
• Monitor CPC planning and execution throughout the acquisition process so that the system design keeps corrosion prevention in mind.

CPC planning should be included in engineering and sustainment documentation such as the systems engineering plan (SEP) and life cycle sustainment plan (LCSP). As the program evolves across its life cycle, CPC planning should be refined and matured. Coupled with this updated August 2022 version of this CPC Guidebook are additional information and resources available in the DoD Corrosion Prevention & Control Community on the DAU website. 

The primary responsibility for this CPC Guidebook resides with the Office of Deputy Assistant Secretary of Defense for Materiel Readiness (Corrosion Policy and Oversight, (CPO)) within Office of the Undersecretary of Defense for Acquisition and Sustainment. The CPO will develop and coordinate updates to this Guidebook as required, based on policy changes and customer feedback. To provide feedback to this document, please contact:

Office of the Deputy Assistant Secretary of Defense for Materiel Readiness 
Corrosion Policy and Oversight 
3000 Defense Pentagon 
Washington, DC 20301 

Related DoD and DAU resources on this important topic include:

• 10 U.S.C. 2228 Office of Corrosion Policy and Oversight
• DoD Instruction 5000.67 Prevention and Mitigation of Corrosion on DoD Military Equipment and Infrastructure
• Corrosion Prevention & Control Community of Practice (CPC CoP)
• Corrosion Prevention & Control ACQuipedia Article
• CLM 038 “Corrosion Prevention and Control Overview” Online Training Course
• CLE 070 “Corrosion and Polymeric Coatings” Online Training Course
• Corrosion Toolbox 

Processes Supported

• Failure Modes & Effects Analysis (FMEA) / Failure Modes Effects & Criticality Analysis (FMECA)
• Failure Reporting, Analysis, and Corrective Action System (FRACAS)
• Corrosion Prevention & Control (CPC)
• Life Cycle Management
• Life Cycle Sustainment Plan (LCSP)
• Maintenance Planning and Maintenance Management

Potential Organizations Associated

• Air Force/ Space Force
• Army
• Defense Agencies
• Navy/ Marine Corps
• OSD/ Joint Staff

License Requirement

• No fee for Government users

Integrated Product Support (IPS) Elements Addressed

• Design Interface
• Maintenance Planning and Management
• Manpower & Personnel
• Sustaining Engineering

Disclaimer
This government tool is included in the product support analytical tools database to assist defense acquisition workforce members with identifying product support solutions which potentially optimize system readiness and life cycle cost. The analytical tools database itself should under no circumstances be considered all-encompassing; nor does it in any way warrant or endorse the capabilities, pricing, and/or products of any particular individual, company, capability, or organization. Suggested updates to the description of this particular tool or additions to the tools database are welcome.