Corrosion Prevention and Control

Corrosion assessments have been a bedrock element of the CPAC program. The Corrosion Assessment Checklist provides a systematic, repeatable process to objectively evaluate and categorize the current condition of military equipment. The output of this process, Corrosion Category Code (CCC), defines specific requirements to improve or sustain equipment condition. The time-proven collection, storage, and archival process for USMC corrosion data directly supports the overarching requirement for military departments to plan, fund, and evaluate military equipment CPC programs.  From a programming perspective, corrosion assessments and subsequent CCC are the core CPAC metric and serve as the basis for all other sustainment requirements. At the tactical level USMC field commands use the CCC to identify exact levels of effort required to restore, repair, or sustain equipment condition.

From an engineer’s perspective, the concept of RTD&E is simple: design the best system and build it using state-of-the-art materials and technologies. The CPAC program takes a holistic approach to RDT&E; one that spans the entire product lifecycle. From Material Solution Analysis to Milestone C decisions and on through to fielding and sustainment, the CPAC RDT&E team is engaged with program managers and field commands alike to provide realistic engineering and technical solutions to corrosion problems. CPAC’s RDT&E efforts are broad in scope and include everything from specific corrosion issues to processes and procedures to technology and materials.

Like assessments, RDT&E equally supports the other pillars; put simply, when RDT&E is done right in acquisitions, then prevention and repair requirements in the field are significantly reduced.

Preventive corrosion control is the first primary element of CPAC. This includes all organizational efforts designed to halt or mitigate equipment degradation caused by the effects of corrosion such as:

• Application of corrosion prevention compounds to stop or significantly retard the onset of corrosion

• Minor surface preparation and touch-up painting operations to remove surface corrosion and maintain coating system integrity

• Operator/Crew Preventive Maintenance Checks and Services (PMCS)

• Equipment washdowns to remove dirt, debris, and other harmful contaminants

• Storage solutions such as protective equipment covers and Controlled Humidity Protection

The USMC CPAC program is unique in that it invests considerably in organizational level direct and indirect support actions, most notably, the Corrosion Service Team. This provides the OPFOR with a consistent, repeatable corrosion prevention solution.

The second primary element of CPAC is corrective corrosion control. The corrosion repair pillar focuses on intermediate maintenance actions (CCC 3 & 4) designed to remove all corrosion products from equipment and restore/re-apply the Chemical Agent Resistant Coating (CARC) system and lifecycle improvement products. The goal of corrosion repair is to return equipment to a CCC 1 condition.

The CPAC program assumes a active sustainment role by providing Field Level corrosion repair services in direct support of the OPFOR.

Two independent levels of corrosion repair are used based on equipment condition and available resources in the area:

Enhanced CST Traditionally, CCC 3 equipment could only be corrected at a regional CRF. In FY 2020, the CPAC program introduced the ECST concept by expanding the scope of the teams’ efforts to include limited CCC 3 corrosion repairs. The level of repair varies and is dependent on each individual team’s available tools and capabilities. Work is performed at the owning unit’s location and is normally completed in approximately five hours.

Corrosion Repair Facility (CRF) CCC 4 and CCC 3 equipment that is beyond Enhanced CST capabilities are inducted by owning units into regional CRFs operated by the CPAC program (via MDMC partnership). These facilities are manned and equipped for large-scale industrial operations including abrasive blasting, body repairs & fabrication, and 100% coating application. Equipment is normally returned to the unit in 45-60 days.

Initial review determines whether the product or material is applicable to Marine Corps CPAC procedures.

1. Product or material is submitted in the Product Testing Request Form

2. CPAC program office evaluates the need for the product and screens for product suitability. If all needs are not met, an additional information request letter will be submitted to the vendor. The product must:

• Meet one of the needs outlined by applicable CPAC Technical Manuals

• Meet appropriate MIL-SPECS or industry standards

• Product or material information submitted regarding application method, PPE requirements, environmental and health hazards, and any other information not found in the MSDS

• NEHC questionnaire completed and NEHC accepted

3. CPAC program office notifies the submitting vendor of results. If the product or material is accepted for evaluation, an acceptance letter is sent to submitting vendor indicating progress to Phase 2: Laboratory Evaluation. If the product or material is not accepted for evaluation, a letter is sent to submitting vendor.

If the submitted product or material passes initial review, the CPAC program office will determine whether a laboratory evaluation is required. If no laboratory evaluation is required, the product or material will move to Phase 3: Field Evaluation.

If laboratory evaluation is deemed necessary, each submitted product or material is assessed individually for its performance, effectiveness, and compatibility with Marine Corps activities. The CPAC program office completes the following:

1. Creates a test plan for submitted product or material. The program office contacts the submitting vendor if additional input is required. After feedback is received, the program office completes the evaluation plan(s)

2. Completes laboratory evaluation and assesses the data

3. Notifies the vendor of the results

• If the product or material passes laboratory evaluation, the program office sends a letter to the submitting vendor indicating progress to Phase 3: Field Evaluation.

• If the product or material does not pass laboratory evaluation, the program office sends a letter to the submitting vendor indicating results.

If the submitted product or material passes laboratory evaluation, the CPAC program office will determine whether a field evaluation is required. If no field evaluation is required, the product or material will move to Phase 4: Completion.

The field evaluation validates laboratory results and validates user application processes and procedures. The CPAC program office will:

1. Prepare a product or material field evaluation plan

• Applicable field evaluations are based on previous testing and intended use. The program office schedules the field evaluation plan and coordinates with a using unit for each submitted product or material.

2. Monitor and analyze the results of the field evaluation(s)

3. Notify the submitting vendor of results

• If the product or material passes field evaluation, the program office sends a letter to the submitting vendor indicating progress to Phase 4: Completion

• If the product or material does not pass field evaluation, the program office sends a letter to the submitting vendor indicating results.

Pending the results of the CPPM process, the CPAC program office will authorize the submission for use and notify the submitter through a formal communication. This gives the user(s) the ability to purchase products at their discretion.

The CPAC program office will:

1. Authorize the product or material for use in applicable CPAC Technical Manuals

2. Send formal communication to the vendor

• Communication will include evaluation results and data applicable to vendor's product or material only

• Communication of product results is limited to the submitting vendor and the CPAC program office