Office of the Secretary of Defense

Department of Defense Report

Efforts to Reduce Corrosion on the Military Equipment and Infrastructure

of the Department of Defense

June 2007

Prepared by the Under Secretary of Defense

(Acquisition, Technology and Logistics)

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Efforts to Reduce Corrosion on the Military Equipment and Infrastructure of the Department of Defense

The Department of Defense is pleased to provide this document outlining our ongoing efforts to reduce corrosion and the effects of corrosion on the Department’s military equipment and infrastructure.1

This report provides the status of key corrosion activities, including the

• results of the 28 corrosion mitigation projects funded in FY2005,

• status of the 54 corrosion mitigation projects funded in FY2006 and FY2007,

• results of the initial phase of the DoD cost of corrosion effort,

• launching of a user-friendly web tool to guide suppliers through the product introduction process,

• status of the Department of Defense Instruction (DoDI) on prevention and mitigation of corrosion on DoD’s military equipment and infrastructure,

• development of a Corrosion Prevention and Control Overview course for the Depart-ment’s acquisition workforce,

• planning for a corrosion study by the National Materials Advisory Board of The National Academies, and

• activity highlights of the seven working integrated product teams (WIPTs): Communica-tion and Outreach; Facilities and Infrastructure; Metrics, Impact, and Sustainment; Policy and Requirements; Science and Technology; Specifications, Standards and Qualification Process; and Training and Certification.

This report updates information contained in the two initial reports to Congress: Long-Term Strategy to Reduce Corrosion and the Effects of Corrosion on the Military Equipment and Infra-structure of the Department of Defense, December 2003, and Status Update on Efforts to Reduce Corrosion and the Effects of Corrosion on the Military Equipment and Infrastructure of the De-partment of Defense, May 2005. Both documents are available on the DoD Corrosion Exchange website (http://www.dodcorrosionexchange.org).

1 Request for an update report was made by Senator Daniel K. Akaka to the DoD Special Assistant for Corro-

sion Policy and Oversight during a meeting on November 19, 2004. Request included updates on the corrosion pro-gram’s projects, activities and the cost-of-corrosion baseline study (after the first phase was completed).

Request was also made by Senator Byron L. Dorgan to the DoD Special Assistant for Corrosion Policy and Oversight during a meeting on June 10, 2005. Request included a revised corrosion strategic plan.

This report is a companion document to GAO-07-618, High-Level Leadership Commitment and Actions Are Needed to Address Corrosion Issues, April 2007.

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COORDINATION VERSION 1 COORDINATION VERSION 1

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Contents Section I Background, Strategy, and Program Status............................................. I-1

BACKGROUND..........................................................................................................................I-2

DOD’S CORROSION STRATEGY................................................................................................I-3

Vision ...............................................................................................................................I-4

Strategies...........................................................................................................................I-4

ORGANIZATIONAL STRUCTURE................................................................................................I-5

SUMMARY OF KEY ACTIVITIES ................................................................................................I-8

REPORT OUTLINE...................................................................................................................I-10

Section II Funding and Personnel Resources Needed to Implement the Strategy............................................................................II-1

PAST AND NEAR TERM........................................................................................................... II-1

LONG TERM ........................................................................................................................... II-1

Section III Selected WIPT Activities................................................................... III-1 POLICY AND REQUIREMENTS WIPT SELECTED ITEM............................................................ III-2

SPECIFICATIONS, STANDARDS, AND QUALIFICATION PROCESS WIPT SELECTED ITEM......... III-3

TRAINING AND CERTIFICATION WIPT SELECTED ITEM ........................................................ III-6

FACILITIES WIPT SELECTED ITEM........................................................................................ III-8

Personnel Training and Certification ............................................................................. III-8

Impact of Corrosion Efforts ........................................................................................... III-8

SCIENCE AND TECHNOLOGY WIPT SELECTED ITEM............................................................. III-9

Develop Joint Service Roadmap for Coordinated S&T................................................. III-9

Establish Knowledge Base by Platform, Infrastructure, and Material Types................ III-9

Provide S&T Interface for the Corrosion IPT................................................................ III-9

Identify R&D Stakeholders............................................................................................ III-9

Maintain Summary Inventory of Corrosion S&T Projects Funding............................ III-10

Identify DoD Corrosion Research Needs Currently Not Being Addressed................. III-10

Facilitate Obtaining Additional or Alternate Funding for Corrosion Research........... III-10

Quantify Current DoD Funding and Research Topics Addressing Corrosion ............ III-10

Augment Project Reliance Inputs ................................................................................ III-10

Aid in Coordinating Research Efforts Among Multiple Services ............................... III-10

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Assist in Managing, Directing, and Coordinating Forthcoming Funding ................... III-11

Provide a Cross-Component Corrosion Forum and Communication Group............... III-11

Provide a Central POC and Broker to Communicate Corrosion Needs ...................... III-11

Establish Knowledge Base (Work with Communication and Outreach WIPT).......... III-11

Develop Websites, Manuals, and Instructions for Corrosion Technologies................ III-11

Establish Mechanisms to Identify Problems and Convey Them to R&D ................... III-11

Continually Review Technology Roadmap from Inception to Implementation.......... III-11

Identify Projects Linked to Common Technology Areas in Major Categories ........... III-11

COMMUNICATIONS AND OUTREACH WIPT SELECTED ITEM............................................... III-12

METRICS, IMPACT, AND SUSTAINMENT WIPT SELECTED ITEM .......................................... III-13

Section IV Status of Cost-of-Corrosion Baseline Study...................................... IV-1 METHODOLOGY .................................................................................................................... IV-1

RESULTS ............................................................................................................................... IV-3

Army Ground Vehicle Corrosion Costs......................................................................... IV-3

Navy Ships Corrosion Costs .......................................................................................... IV-4

Corrosion Cost Focus Areas .......................................................................................... IV-5

SCHEDULE............................................................................................................................. IV-6

Section V Corrosion Reduction Projects .............................................................. V-1 PROJECTS FUNDED IN FY2005............................................................................................... V-1

PROJECTS FUNDED IN FY2006............................................................................................... V-3

PROJECTS FUNDED IN FY2007............................................................................................... V-4

Section VI Detailed Results of Selected FY2005 Projects .................................. VI-1 ARMY FACILITIES: LEAK DETECTION FOR POTABLE WATER LINES AT FORT HOOD.............VI-1

NAVY FACILITIES: RED HILL TUNNEL FUEL LINES...............................................................VI-3

AIR FORCE FACILITIES: SUPERVISORY CONTROL AND DATA AUTOMATION FOR CATHODIC PROTECTION.....................................................................................VI-5

ARMY EQUIPMENT: AMCOM-NAVAIR CORROSION PARTNERSHIP ...................................VI-6

NAVY (NAVAIR) EQUIPMENT: AV-DEC SEALANTS FOR CONDUCTIVE GASKETS...............VI-7

NAVY (NAVSEA) EQUIPMENT: COMPOSITE ELECTRICAL BOXES........................................VI-9

AIR FORCE EQUIPMENT: AIRCRAFT ELECTRICAL CONNECTOR INHIBITOR..........................VI-11

MARINE CORPS EQUIPMENT: AUTOMATED VEHICLE WASH-DOWN SYSTEM .....................VI-13

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Appendix A DoD Corrosion Executive Policy Memorandum

Appendix B Summaries—FY2005 Funded Projects

Appendix C Summaries—FY2006 Funded Projects

Appendix D Summaries—FY2007 Funded Projects

Appendix E Abbreviations

Figures Figure I-1. DoD Corrosion Prevention and Mitigation Strategy ..................................................I-3

Figure I-2. DoD Corrosion Organization......................................................................................I-6

Figure III-1. WIPT Interrelationships ........................................................................................ III-1

Figure III-2. DoD Corrosion Exchange Navigation Bar............................................................ III-4

Figure III-3. Consolidating a Vast Amount of Information....................................................... III-4

Figure III-4. Specification and Standards Selection Tool.......................................................... III-5

Figure III-5. Product Information Form..................................................................................... III-6

Figure III-6. Screenshot of Corrosion Prevention and Control Overview Course .................... III-7

Figure IV-1. Cost-of-Corrosion Data Structure (Army Example)............................................. IV-2

Figure IV-2. Cost of Corrosion for Army Ground Vehicles (FY2004)..................................... IV-4

Figure IV-3. Cost of Corrosion for Navy Ships (FY2004)........................................................ IV-5

Figure VI-1. Ten PermaLog Leak Sensors with a Patroller (Drive-by) Data Retrieval Unit ....VI-2

Figure VI-2. Red Hill Underground Fuel Facility .....................................................................VI-3

Figure VI-3. Red Hill Tunnel Inspection...................................................................................VI-4

Figure VI-4. High Speed Bristle Discs ......................................................................................VI-6

Figure VI-5. Qualifying Aerosol Paints.....................................................................................VI-6

Figure VI-6. Corrosion Preventative Technologies for Avionics..............................................VI-6

Figure VI-7. Magnesium Coatings ............................................................................................VI-7

Figure VI-8. Surface of Aircraft after Antenna Removal ..........................................................VI-8

Figure VI-9. Communications Antenna after Removal (without Av-DEC Gasket)..................VI-8

Figure VI-10. Communications Antenna after Removal (with Av-DEC Gasket).....................VI-8

Figure VI-11. Metallic Electrical Box .......................................................................................VI-9

Figure VI-12. Composite Electrical Box .................................................................................VI-10

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Figure VI-13. Effects of LRU Lubrication (F-16 Aircraft from Shaw AFB)..........................VI-12

Figure VI-14. MCBH Automated Vehicle Wash-Down System.............................................VI-13

Tables Table I-1. Key Corrosion Prevention and Mitigation Activities...................................................I-8

Table II-1. Source and Amount of Corrosion Program Funding Through FY2013 (in millions)........................................................................................................................... II-2

Table III-1. WIPT Interrelationship Examples .......................................................................... III-1

Table III-2. Summary of Key Responsibilities .......................................................................... III-3

Table III-3. CorrDefense Highlights........................................................................................ III-12

Table IV-1. Priority for Acquiring Corrosion Cost Information ............................................... IV-1

Table IV-2. Army Ground Vehicles with the Highest Combined Average Corrosion Cost per Vehicle and Total Corrosion Cost ................................................................................. IV-6

Table IV-3. Navy Ships ESWBS Codes with Highest Contribution to Corrosion Cost............ IV-6

Table IV-4. Schedule of Cost-of-Corrosion Studies.................................................................. IV-7

Table V-1. FY2005 Approved Corrosion Projects and Planned Funding .................................. V-2

Table V-2. FY2006 Approved Corrosion Projects and Planned Funding .................................. V-3

Table V-3. FY2007 Approved Corrosion Projects and Planned Funding .................................. V-5

Table VI-1. Number of Electrical Boxes by Fleet ...................................................................VI-10

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Section I Background, Strategy, and Program Status

It is simply good sense and good management to prevent corrosion through better design and selection of materials, and to reduce treatment costs by detecting corrosion earlier and more precisely. Fighting corrosion is just one of the things that we need to constantly do so that we are always ready to perform the fundamental mission of the Department, which is to maintain our national security.1

—DoD Corrosion Executive

Tremendous effort continues in support of the Department of Defense’s objective of mitigating the safety, readiness, and financial effects of corrosion. Department accomplishments thus far include

• funding and initiation of 82 specific corrosion mitigation projects for 2005 through 2007,

• creation and preliminary coordination of a DoD Instruction on corrosion,

• completion of the cost-of-corrosion study examining the costs related to Army ground vehicles and Navy ships and submarines,

• development of the Corrosion Prevention and Control Overview course hosted at the De-fense Acquisition University (DAU)—targeted to the Department’s acquisition workforce,

• initiation of formalized and standardized training for Corrosion Prevention and Advisory Team (CPAT) members for both equipment and infrastructure, and

• continued refinement of the corrosion project “road map” that identifies specific actions that would prevent or mitigate corrosion.

Despite these and other actions, additional measures must be planned, resourced, scheduled, and accomplished to expand corrosion prevention and mitigation efforts. These measures are detailed in the DoD Corrosion Prevention and Mitigation Strategic Plan.2

1 The Honorable Michael W. Wynne, The AMPTIAC Quarterly, Volume 7, Number 4, Winter 2003, p. 9. 2 The DoD Corrosion Prevention and Mitigation Strategic Plan can be accessed at

http://www.dodcorrosionexchange.org.

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Background The Department of Defense acquires, operates, and maintains a vast array of physical assets, ranging from aircraft, ships, ground combat vehicles, and other materiel to wharves, buildings, utility systems, and other infrastructure. These assets are subject to degradation due to corrosion, with specific effects in the following areas:3

• Safety—Several weapon system mishaps and a number of facility structural failures have been attributed to the effects of corrosion.

• Readiness—Military equipment and infrastructure are sometimes out of commission because of corrosion deficiencies.

• Cost—The cost of corrosion to the DoD is estimated to be between $10 billion and $20 billion annually.

DoD has a long history associated with corrosion prevention and control. The Department has been a leader in many areas of research (ranging from understanding the fundamentals of corro-sion to applying advanced materials, coatings, inhibitors, and cathodic protection for corrosion control); however, it also has very special corrosion-related challenges.

• DoD’s infrastructure is getting older in both relative and absolute terms. The current ex-pected—although often not planned—service lives of some aircraft, missiles, ships, and infrastructure are much longer than most comparable commercial assets.

• In order to perform its mission, the Department must train and fight in all environments, some of which are among the most corrosively aggressive on earth.

• DoD has unique corrosion-related issues. For example, many equipment coatings are formulated to perform some special function, such as resisting chemical agents or main-taining a low infrared signature. Corrosion is, at best, a secondary consideration.

• Like several other DoD efforts, many corrosion activities have been decentralized, which may have decreased their desired visibility and emphasis.

• The Services’ existing financial and logistics information systems cannot precisely identify all corrosion-related programs, costs, and impacts.

To enhance DoD’s efforts, section 1067 of the Bob Stump National Defense Authorization Act for Fiscal Year 2003, Public Law 107-314 (NDAA), enacted in 10 U.S.C. 2228. Section 2228 requires the Secretary of Defense to designate an official or organization to be responsible for the prevention and mitigation of corrosion of military equipment and infrastructure. It also requires the development and implementation of a long-term strategy. The long-term strategy was originally published in November 2004 and the most recent update is accessible on http://www.dodcorrosionexchange.org. The strategy is updated annually (at a minimum) so that it remains current and relevant.

3 United States Government Accountability Office, Opportunities to Reduce Corrosion Costs and Increase

Readiness, GAO-03-753, July 2003, p. 3.

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The Government Accountability Office completed four recent corrosion-related audits:

• GAO-03-753, Opportunities to Reduce Corrosion Costs and Increase Readiness, July 2003, recommended the DoD corrosion strategic plan (then in development) address a number of issues, including performance measures, standard project evaluation criteria, and inter-service coordination of projects.

• GAO-04-640, Opportunities Exist to Improve Implementation of DoD’s Long-Term Corrosion Strategy, June 2004, acknowledged ongoing DoD efforts but identified areas that require increased emphasis.

• GAO-06-709, Additional Measures to Reduce Corrosion of Prepositioned Military Assets Could Achieve Cost Savings, June 2006, recommended the Army examine the feasibility of using temporary shelters to store land-based pre-positioned assets, and the Army and Marine Corps enhance their efforts to collect corrosion-related data on prepositioned assets.

• GAO-07-618, High-Level Leadership Commitment and Actions Are Needed to Address Cor-rosion Issues, April 2007, recommended areas for additional attention and enhancement.

DoD’s Corrosion Strategy Figure I-1 depicts the approach DoD used in developing its corrosion strategy.

Figure I-1. DoD Corrosion Prevention and Mitigation Strategy

Appoint Responsible

Officials

Identify DoD Corrosion

Requirements

Office of Corrosion Policy and Oversight

Create Organizational

Structure

Integrated Product Team

Establish Policy

Define Mission

Determine Approach

Formulate and Execute Plan

Establish Vision

Strategic Plan Framework

The activities depicted above are discussed in detail in the December 2003 corrosion report to Con-gress4 and the DoD Strategic Plan for Corrosion Prevention and Mitigation. Both reports are acces-sible at http://www.dodcorrosionexchange.org. This section briefly highlights the key aspects of the strategy.

4 Department of Defense, Report to Congress, Long-Term Strategy to Reduce Corrosion and the Effects of Cor-

rosion on the Military Equipment and Infrastructure of the Department of Defense, December 2003.

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Vision The overall corrosion prevention and mitigation vision reveals a new DoD-wide culture that considers the long-term effects of corrosion, sets boundaries on the cost of corrosion, implements sound corrosion preven-tion and mitigation policies for both equipment and infrastructure, and establishes realistic metrics to evaluate the effectiveness of these policies and resulting programs. This culture permeates the military, industrial, and academic sectors, creating new approaches for characterizing, pre-venting, and treating corrosion and mitigating its effects.

Within this new culture, significant actions by DoD, industry, and acade-mia accelerate the modernization of equipment and infrastructure; close unneeded facilities; improve the corrosion resistance of materials in new products, systems, and facilities; predict the potential for corrosion to occur and its effects; and implement affordable methods of corrosion detection and mitigation, including improved condition-based mainte-nance. Universities emphasize corrosion prevention, control, and mitigation in curricula devoted to material selection during design. Likewise, DoD implements standard procedures for selecting and applying existing specifications and standards and for revising or creating new specifications and standards. Both military customers and industrial suppliers benefit from the standard appli-cation of these processes for product or system qualification, verification, and validation.

DEPARTMENT OF DEFENSE

CORROSION PREVENTION AND MITIGATION STRATEGIC PLAN

CORROSION POLICY AND OVERSIGHT OFFICE Update November 2006

The responsibility for policy making, strategic direction, and standardization resides with the Office of the Secretary of Defense (OSD). However the Defense Agencies and the Military Departments continue to develop and implement strategic plans that are consistent with Department-wide plans and objectives. The established procedures of each Military Department hold major commands and program offices that manage equipment and infrastructure accountable for achieving the strategic goals. Nevertheless, corrosion prevention is a Joint Service effort, with continuous exchange of tech-nologies, processes, and results.

The précis of DoD’s corrosion prevention and control vision is one of safe and affordable equipment and facilities that perform at the level of quality for which they were procured; are available to perform their function when they are needed; and can be acquired, operated, and maintained at a reasonable cost. Envisioned results include reduction in corrosion-related mis-haps, increased equipment and infrastructure availability, and the lowest possible corrosion-related life-cycle costs (consistent with such variables as equipment age, operating tempo, and funding of corrosion prevention projects).

Strategies The overarching corrosion prevention and mitigation strategy is to transcend traditional corro-sion control methods, organizations, management, and funding approaches and to apply modern technology and management techniques to prevent and control corrosion throughout the life-cycle of systems, facilities, and materials.

• Implement a dynamic and effective corrosion prevention and control organization at the highest level in the Office of the Secretary of Defense.

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• Attack corrosion early in the acquisition or construction cycle—during design, manufac-turing, assembly, and construction.

• Focus life-cycle corrosion research and development efforts on four primary areas

Materials and manufacturing processes that prevent or reduce the incidence and ef-fects of corrosion

Detection of the incidence, nature, and severity of corrosion in fielded systems and facilities as well as prognosis of the expected growth progression, potential impact, and predicted effects of mitigation actions

Coatings, treatments, corrosion inhibitors, cathodic protection, moisture mitigation, and other applications to prevent, arrest, or retard corrosion, with emphasis on sus-tainable or “green” technologies

Repair processes that restore corroded materials to an acceptable level of structural integrity and functionality.

• Use every available communication channel to receive and convey all aspects of corro-sion—nature, impact, approaches, and results—from and to every organization within the broad Department of Defense and industry communities.

• Work with and leverage the expertise of relevant professional societies and industry groups.

• Modernize corrosion specifications, standards, and other requirements, and develop stan-dard, streamlined product introduction process for suppliers of corrosion-prevention tech-nologies and products.

• Conduct studies and surveys, collect data, and analyze results to determine the impact of corrosion, pinpoint critical areas for concentration of prevention and mitigation efforts, and develop metrics to measure the effect of corrosion and the results of prevention and mitigation efforts.

• Publish and distribute direction and guidance that provide adequate details and instructions regarding implementation of corrosion prevention and mitigation policies and strategies and that apply to all levels of leadership and management in the DoD and Services.

• Conduct focused corrosion prevention and mitigation training that is tailored to the learn-ing requirements at each management and technical level in the DoD and Services.

• Demonstrate and validate emerging corrosion control technologies to determine their suitability for DoD-wide applications.

Organizational Structure Figure I-2 reflects the current structure of the DoD corrosion prevention and control organiza-tion. In particular, the placement of the Special Assistant for Corrosion Policy and Oversight un-der the Deputy Under Secretary of Defense, Acquisition and Technology (DUSD(A&T)), is enhancing the Department’s ability to insert corrosion mitigation products and processes into its acquisition programs. Lines of coordination remain with other key Under Secretary of Defense for Acquisitions, Technology, and Logistics (USD(AT&L)) functions, including DUSD,

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Logistics and Materiel Readiness; DUSD, Installations and Environment; and the Director, De-fense Research and Engineering.

A central facet of DoD’s Corrosion Control and Oversight Program is the Corrosion Prevention and Control (CPC) Integrated Product Team (IPT) depicted in the lower portion of Figure I-2.

Figure I-2. DoD Corrosion Organization

Director, Defense Research and EngineeringDUSD, Science and Technology

DUSD, Installations and Environment

Policy and Requirements

Training and Certification

FacilitiesCommunication and Outreach

Metrics, Impact and Sustainment

Specifications, Standards and Qualification Process

• OSD• Joint Staff/J4• Army• Navy• Air Force• Marine Corps

• Army Corps of Engineers • United States Coast Guard• Joint Council on Aging Aircraft• National Aeronautics and Space Administration• Defense Logistics Agency• General Services Administration

IPT member representatives

Science and Technology

DoD Corrosion Prevention and Control IPT

Special Assistant for Corrosion Policy and Oversight

USDAcquisition, Technology, and Logistics

DoD Corrosion Executive

DUSD A&TDirector, A&T, Systems and Software Engineering

DUSD, Logistics and MaterielReadiness

The Deputy Secretary of Defense designated the Principal Deputy Under Secretary of Defense for Acquisition, Technology, and Logistics (PDUSD(AT&L)) as the responsible corrosion offi-cial.5 However, the USD(AT&L) is the DoD Corrosion when a PDUSD(AT&L) is not desig-nated or when the USD(AT&L) elects to assume this responsibility. The Corrosion Executive provides oversight and coordination for corrosion prevention and control

• during design, acquisition, and maintenance of military equipment;

• during design, construction, and maintenance of infrastructure;

• by monitoring DoD acquisition practices; and

• by ensuring the use and application of corrosion prevention treatments are fully considered during research and development as well as during acquisition, engineering and design.

5 Deputy Secretary of Defense Memorandum, “Delegation of Corrosion Official for the Department of

Defense," May 8, 2003.

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The Corrosion Executive established a Corrosion Policy and Oversight Office—headed by the Spe-cial Assistant for Corrosion Policy and Oversight in Defense Systems—that is responsible for fa-cilitating the establishment of a viable corrosion prevention control and mitigation program for both equipment and infrastructure in the Department of Defense. The Special Assistant also has the responsibility to lead the CPC IPT.

Chartered on September 3, 2003, the CPC IPT is responsible for developing strategic direction, policy, and guidance to prevent and mitigate corrosion of the military equipment and infrastruc-ture of the Department. The specific goals of the CPC IPT include

• providing strategic review and advice as necessary to address congressional requirements,

• developing and recommending policy guidance,

• developing a road map and monitoring the progress of corrosion-related activities, and

• developing strategies to efficiently track corrosion costs and their effect on readiness and safety.

As stated, working integrated product teams (WIPTs) were established to address the various corrosion focus areas. These WIPTs meet as a group during “corrosion forums” (14 forums have been held to date) and targeted workshops, such as those that recently focused on training and specifications and standards. Corrosion forum accomplishments include the

• drafting of policy documents,

• preparation of performance measures,

• development of project submission and approval methods,

• preparation and updating of the CPC Planning Guidebook, and

• enhancement of information cross-flow among the functional representatives from the Services and OSD.

In summary, the DoD corrosion prevention and mitigation organization provides the structure and management oversight necessary to fully address both the material (prevention, detection, prediction, and management) and non-material (e.g., training, standards, cost study, and policy) aspects of the program. This integrated approach will continue to target solutions for both mate-rial and non-material issues. Specific material-related projects are detailed in Sections V and VI and Appendices B, C, and D. Non-material-related activities are contained in Sections III and IV.

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Summary of Key Activities The following is a chronology of key DoD corrosion prevention and mitigation activities since the passage of 10 U.S.C Section 2228.

Table I-1. Key Corrosion Prevention and Mitigation Activities

Month Activity

December 2002 Section 1067 (NDAA) and10 U.S.C. 2228 require specific DoD corrosion-related actions, including the development of a long-term strategy to mitigate corrosion

January 2003 Establishment of DoD Corrosion Control and Oversight organization May 2003 Deputy Secretary of Defense Memorandum, “Delegation of Corrosion Official for the

Department of Defense,” is signed and promulgated. May 2003 Submission of Interim Report to Congress August 2003 Publication of Corrosion Project Plan template (for assessment of new projects) September 2003 DoD corrosion website established to exchange corrosion-related information

Corrosion Prevention and Control IPT charter approved Beneficial working relationships established with key organizations, including NACE Interna-tional and the Society for Protective Coatings CPC input provided to 5000 Final Guidebook

October 2003

CPC input provided to DPG and Programming and Budgeting Activity DoD Corrosion Policy approved and promulgated DoD CPC Planning Guidebook completed (Spiral 1) Advanced Materials & Processes Technology Information Analysis Center (AMPTIAC) special corrosion issue published Tri-Service Corrosion Conference conducted Inclusion of CPC in the Designing and Assessing Supportability in DoD Weapon Systems Guidebook

November 2003

DoD Corrosion Executive charters a Defense Science Board on Corrosion Control December 2003 DoD Long-Term Corrosion Strategy report submitted to Congress January 2004 Corrosion content added to selected Defense Acquisition University (DAU) courses

CPC IPT Corrosion Training Summit held Start of DAU rapid deployment CPC policy/planning training for AT&L workforce

February 2004

PDUSD(AT&L) corrosion-related video stream included in DAU curriculum March/April 2004 “DoD CPC Status and Update” published in Defense AT&L magazine (22,000 distribution) June 2004 Defense Logistics Agency (DLA) briefed Corrosion Forum V on tits Reliability Engineer-

ing Initiative, including examples of corrosion mitigation projects July 2004 DoD CPC Planning Guidebook completed (Spiral 2)

Requirement to address corrosion in acquisition plans added to the DFARS September 2004 Funding provided for improved reliability of parts managed by DLA

October 2004 Defense Science Board on Corrosion Control publishes report Strategic Plan for Corrosion Prevention and Mitigation published November 2004 The position of Special Assistant for Corrosion Control and Oversight was established

December 2004 Phase I of the SSQP effort completed (corrosion-related specifications/standards added to the corrosion website)

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Table I-1. Key Corrosion Prevention and Mitigation Activities

Month Activity

Services commenced 28 approved corrosion projects January 2005

Program commenced cost-of-corrosion study effort October 2005 First issue of CorrDefense published

November 2005 Tri-Service Corrosion Conference held with sponsorship by DoD Corrosion Office and expanded to include facilities and sustainment

March 2006 Phase II of the Specifications, Standards, and Qualification Process (SSQP) effort com-pleted (built upon the specifications and standards matrix and focused on the develop-ment of the web-based product introduction process tool)

April 2006 Phase III of the SSQP effort commences (will address suppliers who either have a prod-uct that is fundamentally different to anything the DoD has used, or are proposing a dif-ferent application for an existing product)

April 2006 Program managers handbook completed April 2006 First phase of the cost of corrosion baseline study successfully completed (Army ground

vehicles and Navy ships) July 2006 First Corrosion Prevention Advisory Team workshop conducted November 2006 Corrosion bi-lateral interchange meeting with personnel from the Australian Ministry of

Defence December 2006 Communications and Outreach corrosion video effort initiated December 2006 Under the auspices of the Corrosion Education Consortium, the University of Akron an-

nounces its plan to offer a bachelors of science degree in corrosion engineering—the first in the nation

January 2007 Kick-off corrosion planning meeting with the National Academy of Sciences April 2007 CPC Overview course completed and added to DAU curriculum April 2007 Second phase of the cost of corrosion baseline study successfully completed (DoD facili-

ties/infrastructure, Army aviation/missiles, and Marine Corps ground vehicles) May 2007 Third phase of the cost of corrosion baseline study scheduled to begin (Navy aviation,

U.S. Marine Corps (USMC) aviation, U.S. Coast Guard (USCG) aviation, and USCG ships)

August 2007 Corrosion DoD Instruction scheduled to be approved and promulgated

December 2007 Tri-Service Corrosion Conference, under the leadership of the DoD Corrosion Office, scheduled to be held in Denver, Colorado

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Report Outline The remainder of this report is outlined as follows:

• Section II Funding and Personnel Resources Needed to Implement the Strategy

• Section III Selected WIPT Activities

• Section IV Status of Cost-of-Corrosion Baseline Study

• Section V Cost Reduction Projects

• Section VI Detailed Results of Selected FY2005 Projects

Appendices are:

• Appendix A DoD Corrosion Executive Policy Memorandum

• Appendix B Summaries—FY2005 Funded Projects

• Appendix C Summaries—FY2006 Funded Projects

• Appendix D Summaries—FY2007 Funded Projects

• Appendix E Abbreviations

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Section II Funding and Personnel Resources Needed to Implement the Strategy

The term “corrosion” means the deterioration of a material or its properties due to a reaction of that material with its chemical environment.1

This section details the resource planning that will enable the Department’s corrosion policy and oversight function to successfully meet the milestones outlined in the Strategic Plan.

Past and Near Term During FY2003 and FY2004, program funding came from reallocated OUSD(AT&L) resources. The funding supported program start-up requirements and included a number of specific efforts: the development of the DoD corrosion planning guidebook, identification and stratification of corrosion-related specifications and standards, development of the Strategic Plan, identification of acquisition workforce corrosion training requirements, and the creation of project plan tem-plates. In addition, the resourcing supported the preliminary planning of other key objectives, such as the cost-of-corrosion study and corrosion training requirements.

The FY2005 budget was the first that employed the Planning, Programming, Budgeting, and Execution (PPBE) system. For FY2005, $27 million was approved and allocated—$17.5 million for 28 Service corrosion projects, and $9.5 million for CPC activities, including policy imple-mentation (e.g., cost-of-corrosion study, communications (website), and CPC IPT support), cor-rosion training and certification, specifications and standards assessments, and product qualification process enhancement.

For FY2006, the $15.1 million budget was used to fund 29 projects ($11.7 million) and CPC ac-tivities ($3.4 million). For FY2007, the $13.4 million budget is being used to support 25 projects ($7.6 million) and CPC activities and policy implementation ($5.8 million).

Details of the approved projects are contained in the appendices.

Long Term A long-term resourcing approach has been developed and implemented in the Department’s PPBE process. A funding request totaling about $14.5 million was included in the President’s FY2008 budget submission. Table II-1 depicts the source and amount of corrosion program funding through FY2013.

1 From Section 1067 of the Bob Stump National Defense Authorization Act (NDAA) for Fiscal Year 2003,

Public Law 107-314, enacted as 10 U.S.C. 2228.

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Table II-1. Source and Amount of Corrosion Program Funding Through FY2013 (in millions)

Funding Source FY20

05

FY20

06

FY20

07

FY20

08

FY20

09

FY20

10

FY20

11

FY20

12

FY20

13

DoD CPC O&M – $8.136 $8.151 $8.101 $9.060 $9.044 $8.543 $8.764 $8.990

Army CPC O&M $9 – – – – – – – –

Navy CPC O&M $7 – – – – – – – –

USAF CPC O&M $9 – – – – – – – –

USMC CPC O&M $2 – – – – – – – –

DoD CPC RDT&E – $7.402 $7.125 $4.983 $5.110 $5.098 $4.858 $4.984 $5.112

Total $27 $15.538 $15.276 $13.084 $14.170 $14.142 $13.401 $13.748 $14.102 Note: Table does not include Service matching or complementary project funding which is identified in Tables V-1, V-2 and V-3.

One of the central objectives of the program is to leverage available program resources (person-nel and funding) to “germinate” continuing corrosion mitigation progress within OSD and the Services. The following are examples of personnel supporting the program’s efforts:

• Active and continuing support from more than 50 CPC IPT and Corrosion Forum personnel

• Corrosion Prevention Advisory Team (personnel assigned to support acquisition program requirements)

• Support contractors accomplishing specific tasks, including the cost-of-corrosion study, Corrosion Prevention and Control Overview course development, identification of main-tainer corrosion training and certification requirements, Corrosion Exchange website maintenance, refining pertinent specifications and standards, leading CPAT workshops, and refining the product qualification process

• Defense Systems Assessment Team—approximately 10 people

• Increased numbers of acquisition workforce personnel trained in corrosion awareness by the Defense Acquisition University.

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Section III Selected WIPT Activities

The seven components of DoD’s long-term corrosion strategy—as represented by the CPC IPT’s seven WIPTs—form the foundation of the Department’s prevention and mitigation efforts. Al-though these separate components cover the breadth and depth of corrosion initiatives and enable a compartmentalized focus by the WIPTs, they are interrelated (as depicted in Figure III-1) and con-stitute the cohesive basis for both short- and long-term actions. This section provides an expanded description of one significant accomplishment from each WIPT. Details of each WIPT’s activities are contained in the DoD Corrosion Prevention and Mitigation Strategic Plan.

Figure III-1. WIPT Interrelationships

Policy & Requirements

Training & Certification

Facilities

Specifications, Standards & Product Qualification

Science & Technology

Metrics, Impact & Sustainment

Communications & Outreach

Examples involving each WIPT are depicted in Table III-1.

Table III-1. WIPT Interrelationship Examples

Lead WIPT Supported WIPT Connectivity

Policy & Requirements All Approval of corrosion DoD Instruction will lead to coordinated and stan-dardized corrosion prevention and mitigation efforts throughout the De-partment

Science & Technology Metrics, Impact & Sustainment

Advances in S&T are expected to reduce sustainment costs, labor, and deployment footprint

SSQP Communications & Outreach

Developing the specifications and standards matrix and the product introduction process with hosting on the Corrosion Exchange website will help suppliers as well as the Department

Training & Certification Metrics, Impact & Sustainment

Training of CPAT members will enhance the systems when they are fielded

Metrics, Impact & Sustainment

Facilities Results of cost of corrosion studies enable the Services to make re-fined resource allocation decisions

Facilities Training & Certification

CPC training and certification classes arranged through NACE and SSPC will enhance the qualifications and capability of the DoD workforce

Training & Certification Science & Technology

Development of the Corrosion Prevention and Control Overview course highlights the need for the acquisition community to make enhanced materials selection decisions

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Table III-1. WIPT Interrelationship Examples

Lead WIPT Supported WIPT Connectivity

Facilities Metrics, Impact & Sustainment

Impacts of corrosion study efforts will assist MIS overall cost of corro-sion baseline study effort, and initiate process to modify the Facilities Sustainment Model to account for CPC

Policy & Requirements Training & Certi-fication

DFARS change now requires the consideration of corrosion and sup-ports CPAT members (and their training)

Communications & Outreach

Policy & Requirements

Communicates DoD’s policies and initiatives to the public and private sectors

Policy and Requirements WIPT Selected Item

Policy Memorandums

Directives

Army Corrosion Guidance

Acquisition Guidance

Corrosion DoDI

Public Law

Navy & USMC Corrosion Guidance

Air Force Corrosion Guidance

CPCIPT Guidance

Policy Memorandums

Directives

Army Corrosion Guidance

Acquisition Guidance

Corrosion DoDI

Public Law

Navy & USMC Corrosion Guidance

Air Force Corrosion Guidance

CPCIPT Guidance

An indispensable corrosion program requirement—the development, approval, and promulgation of a corrosion-related DoD Instruction—is being addressed successfully.

When approved, the DoD Instruction will pro-vide essential linkages with numerous guidance documents, including public law, policy memo-randums, acquisition guidance, DoD directives, CPC IPT guidance, and individual Service in-structions and manuals.

The DoD Instruction, Prevention and Mitigation of Corrosion on DoD Military Equipment and Infrastructure, will provide key Departmental policy, including

• requiring acquisition strategies and trade-off decisions involving cost, useful service life, and effectiveness to address corrosion prevention and mitigation;

• implementing corrosion prevention and control (CPC) programs and preservation tech-niques throughout the life cycle of all military equipment and infrastructure; and

• CPC reporting shall provide for data collection, archiving, and feedback.

In addition, the DoD Instruction will detail responsibilities for the DoD Corrosion Executive and the heads of DoD components. Table III-2 summarizes those key responsibilities.

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Table III-2. Summary of Key Responsibilities

Individual Responsibilities

Oversee and coordinate efforts throughout the Department to prevent and mitigate corrosion of the military equipment and infrastructure Develop and recommend policy and guidance on the prevention and mitigation of corrosion Annually report to the Secretary of Defense recommendations pertaining to the Mili-tary Departments’ corrosion prevention and mitigation programs and funding levels Provide oversight and coordination of the efforts within the Department to prevent or mitigate corrosion Designate an individual to be the Special Assistant for Corrosion Policy and Oversight (SA/CPO) Develop and implement an overarching, long-term corrosion prevention and mitigation strategy

DoD Corrosion Executive

Establish a set of performance measures and milestones to manage the program and quantify results Designate a point of contact (POC) (a senior individual or office) for oversight of corrosion matters, identified to the SA/CPO Establish a process to review and evaluate corrosion planning Support the CPC IPT process

Heads of DoD Components

Establish procedures to review corrosion-related specifications, standards, product test protocols, and qualified products lists

Specifications, Standards, and Qualification Process WIPT Selected Item Until recently, product suppliers looking to introduce their CPC product or service to the DoD frequently encountered a painstaking process. Without a centralized source, finding the right in-formation and knowing who to contact was not easy. Suppliers familiar with these difficulties now have reason to celebrate.

The DoD Office of Corrosion Policy and Oversight has developed and launched a sophisticated and user-friendly web tool to guide suppliers through the product introduction process. This web tool hosted on the DoD Corrosion Exchange website (http://www.dodcorrosionexchange.org, has essentially consolidated and facilitated the process for CPC product suppliers. One of the main problems for suppliers has been the myriad points of contact, and figuring out which to use was not always straightforward. In addition, product requirements vary from agency to agency, and helpful information for introducing a product was spread out and difficult to collect. Suppliers had to perform time-consuming searches or hire consultants to find what they were looking for. Now all of that information is in one place. 1

In the past, the process has been very frustrating for some companies. For instance, many suppli-ers have the impression that each Service has a separate product qualification program. A com-pany may finally get their product qualified for an Army program, but may have to go through additional testing for use within a Navy program, which is an example of product qualification

1 Information extracted from CorrDefense, “ DoD Launches Online Tool to Facilitate the Introduction of CPC Products to the Services,” Ben Craig, Volume 2, Number 3, Fall 2006.

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versus product authorization. In this example the product may have been qualified against an Army product specification, but it requires additional testing to verify the product will meet the mission requirements of the Navy program, which conducts its mission within a different opera-tional environment than the Army. Industry was looking for one person, one office, and one place where they could go to find out how to sell their product or who to talk to. At least for CPC products, information on the DoD process for product introduction path has now been con-solidated and described.

The Specifications, Standards and Qualification Process (SSQP) WIPT designed and devel-oped the Product Introduction Process web tool. The tool is designed to help suppliers match their product to specifications and standards utilized by the DoD for corrosion prevention and control. To step into the product introduction process, the user can move the cursor over Product Introduction on the navigation bar (Figure III-2) on the DoD Corrosion Exchange website, and click on Product Introduction Process. The steps that follow (depicted in Figures III-3 and III-4) help the user select applicable specifications that have product requirements similar to the char-acteristics of the user’s product or process

Figure III-2. DoD Corrosion Exchange Navigation Bar

Note: Specs and Standards Matrix developed under Phase I.

Figure III-3. Consolidating a Vast Amount of Information

Note: A user can select the specifications and standards that are applicable to his or her product.

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Figure III-4. Specification and Standards Selection Tool

Thus, when suppliers describe their product, the tool guides them to a specific group of specifi-cations or standards that may be applicable. Once suppliers select the appropriate specification or standard, the web tool will lead them down the rest of the path on how to introduce their product to the DoD.

The refined web utility is the result of completing Phase II of a three-phase SSQP project. The product introduction process tool has consolidated a vast amount of information. In the first phase of the project, the SSQP WIPT identified more than 16,000 specifications and standards related to corrosion. After reviewing and categorizing these records, the list of relevant specs and standards was narrowed to 862, which were then incorporated into a detailed matrix. Phase II of the project built upon this specifications and standards matrix and focused on the development of the web-based product introduction process tool.

The web-based product introduction tool will not only benefit industry, it will help the DoD ac-celerate the transition of better products from industry to implementation on DoD assets. The web tool provides the information resources and, in some instances, testing requirements, it guides the supplier through the appropriate process for introducing their product. The tool then provides information that helps the user identify the contact information for the appropriate gov-ernment point of contact or office. Once the applicable specifications have been identified and selected, the web tool provides instructions on how to proceed for that specification or standard. For example, for specifications requiring formal qualification, the user will need to submit a formal request for testing to the appropriate cognizant agency point of contact.

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Using another feature of the online tool the user may save his or her progress at any time in a Product Information Form (Figure III-5), which is available on the DoD Corrosion Exchange homepage the next time the user logs in. It is important to note that the web-based tool, in itself, does not qualify a product nor does it guarantee procurement of the product by the DoD.

Figure III-5. Product Information Form

The website is accessible to anyone. The only stipulation is that individuals need to register on the DoD Corrosion Exchange website, however the membership is free.

Phase III of the project was initiated in April 2006, even before completion of Phase II. This next phase of the project will address suppliers who either have a product that is fundamentally dif-ferent to everything the DoD has used in the past or who are proposing a different application for an existing product.

Training and Certification WIPT Selected Item The Training and Certification WIPT has had numerous accomplishments, including commenc-ing training for Corrosion Prevention and Advisory Team members, prioritizing corrosion train-ing requirements for the Department’s sustainment workforce, and investigating corrosion certification requirements and processes.

A major effort of the Training and Certification WIPT focused on enhancing the corrosion train-ing of the DoD acquisition workforce because, as stated by the DoD Corrosion Executive: 2

It is simple good sense and good management to prevent corrosion through better design and selection of materials, and to reduce treatment costs by detecting corrosion earlier and more precisely.

2 The AMPTIAC Quarterly, Volume 7, Number 4, Winter 2003, p. 9.

As a result, corrosion content was added to selected DAU courses for program managers, acqui-sition logisticians, systems engineers, facility engineers, and contracting personnel. In addition, the WIPT led the development of a completely new corrosion-oriented DAU distance learning module (DLM). The Corrosion Prevention and Control Overview (CP&CO) DLM supplements classroom education with additional corrosion information for students most likely to influence corrosion-related acquisition decisions. The CP&CO DLM consists of six modules that students can self-navigate to cover specific subject areas:

• Introduction to Corrosion

• Planning, Implementation, and Management

• Corrosion Characteristics, Effects, and Treatment

• Preventing Corrosion

• Controlling Corrosion

• Nonmetallic Material Degradation.

Figure III-6 is screenshot from the CP&CO DLM.

Figure III-6. Screenshot of Corrosion Prevention and Control Overview Course

Finally, two additional DLM courses are planned. Once fully developed, the three courses will escalate the level of understanding for corrosion prevention from awareness to comprehension and finally application. This overall program will give the Department’s acquisition community the knowledge necessary to fully consider corrosion when making relevant acquisition decisions.

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Facilities WIPT Selected Item With representatives from the Army, Air Force, Navy, Defense Logistics Agency (DLA), DUSD for Installations and Environment (DUSD(I&E)), and industry organizations, the Facilities WIPT was established to identify and establish strategies that address CPC infrastructure issues and, when appropriate, interrelate with the other six WIPTs and resolve infrastructure concerns related to each. In the past 2 years, the Facilities WIPT concentrated its efforts on training and certification issues in connection with the Training and Certification WIPT and the preliminary impact of cor-rosion efforts in connection with the Metrics, Impact, and Sustainment (MIS) WIPT.

Personnel Training and Certification Installation and headquarters-level personnel cited the need for CPC training and certification for engineers and trades people to improve workforce skills and knowledge. Certain aspects of fa-cilities CPC, such as corrosion protection for underground storage tanks, requires certification of personnel performing such work in order to comply with environmental and safety laws. The Fa-cilities WIPT led an effort, coordinating with NACE International (formerly the National Asso-ciation of Corrosion Engineers) and the Society of Protective Coatings (SSPC), to arrange for CPC training that would lead to certification of both equipment and infrastructure personnel. In all, more than 300 DoD personnel have received training (and certification) in basic corrosion and corrosion control, protective coatings, and cathodic protection.

Impact of Corrosion Efforts With DUSD(I&E) support, the Facilities WIPT commissioned a study to develop metrics to de-termine the impact of corrosion on DoD facilities and the potential benefit of implementing cor-rosion prevention technologies. The purpose of the study was to

• develop metrics and algorithms for determining impact of corrosion and benefits of cor-rosion prevention and control at DoD installations;

• collect and evaluate data from field surveys at three DoD installations to validate these metrics and algorithms and identify

areas of active corrosion and associated costs to repair facilities damage caused by corrosion and

the associated savings that can be realized with an effective corrosion control program;

• determine the adequacy of existing base corrosion control efforts at the three installa-tions, provide recommendations and budget cost estimates to improve these efforts, and determine the priority for funding the different CPC initiatives; and

• identify potential cost savings, analyze costs, document the facility corrosion prevention requirements necessary for compliance with underground storage tank laws and recently issued OSD policy, and provide specific facility guidance for implementation.

In addition, the preliminary efforts established the foundation for the MIS WIPT effort in conducting the overall cost of corrosion baseline study and initiate a process to modify the Facilities Sustainment

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Model to account for corrosion prevention and control. The final report for this effort was completed in 2006.

Science and Technology WIPT Selected Item The Science and Technology (S&T) WIPT was established to ensure a continuous interchange and liaison with DoD corrosion research personnel and programs. It augments but does not du-plicate the broad-based DoD strategic planning activity known as Reliance-21. DoD corrosion S&T projects and plans remain within the Joint Warfighting Science and Technology Plan, the Basic Research Plan, Materials and Processes Joint Program Plan, and roadmaps. To integrate S&T within the CPC IPT and establish a bridge to S&T managers and planners, the S&T WIPT developed a roadmap of actions and functions specific to the CPC area. A summary of the ac-tions taken, progress made, and status is as follows.

Develop Joint Service Roadmap for Coordinated S&T The CPC Corrosion Prevention and Mitigation Strategic Plan includes a summary of the corro-sion programs and major projects being pursued by the Components of the DoD. Corrosion planning and overall roadmapping in S&T will be accomplished within the Materials and Proc-esses Technology Focus Team, which brings together materials, civil engineering, environmental quality, infrastructure, and manufacturing technology programs for the purposes of joint plan-ning and collaboration. This will be an ongoing activity within the S&T WIPT. The S&T WIPT will continue to rationalize the S&T roadmap with other research, development, test, and evalua-tion (RDT&E) projects and provide feedback to S&T and other decision makers relative to pro-gram gaps and developing needs.

Establish Knowledge Base by Platform, Infrastructure, and Material Types This action area constitutes a long-term commitment by the S&T community and program man-agers to work with acquisition, logistics, and facilities in identifying corrosion issues and needs. It includes a number of subtasks with status discussed in the following sections.

Provide S&T Interface for the Corrosion IPT The members of the S&T WIPT have been formally established as a liaison between the CPC IPT and all S&T programs that relate to corrosion. The S&T WIPT has supported the Defense Science Board, Program Executive Officers/Systems Commands Conference and Workshops, Maintenance Technology Symposium, Maintenance Technology Senior Steering Group, the University Corrosion Consortium, the National Materials Advisory Board (National Research Council), and other planning and liaison activities in its overview and evaluation of S&T programs, products, and needs.

Identify R&D Stakeholders The S&T WIPT has established linkages to Logistics and Materiel Readiness, the Joint Staff, De-fense Systems (Acquisition), and Tri-Service Installations Management. Members of the WIPT

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are actively participating in technology readiness assessments and corrosion planning evaluations as part of defense acquisition.

Maintain Summary Inventory of Corrosion S&T Projects Funding An overview of S&T corrosion projects is included in the Corrosion Prevention and Mitigation Strategic Plan. Current and planned funding has been included in the Materials and Processes Joint Program Plan. Funding plans are updated annually based on the President’s Budget and congressional appropriations.

Identify DoD Corrosion Research Needs Currently Not Being Addressed Corrosion research needs identified by the CPC IPT and evaluated by the S&T WIPT were used to establish focus areas for the FY2004 Small Business Innovation Research Initiative (described be-low). Corrosion research needs is an ongoing activity and were a special focus topic in the Materials and Processes Technology Area Review and Assessment in March 2006. The S&T WIPT will con-tinue to utilize the DoD Corrosion Exchange website as a medium of needs capture and discussion.

Facilitate Obtaining Additional or Alternate Funding for Corrosion Research The S&T WIPT has focused on two areas for additional support and funding. First, issues identi-fied by the CPC IPT were incorporated in a Pentagon Small Business Innovation Research (SBIR) Initiative. This initiative, which was posted in early May 2004, added 17 new corrosion-specific topics to the DoD SBIR program, augmenting the typically 6 to 10 SBIR corrosion top-ics within Service SBIR programs. Phase II SBIR contracts are now underway for these topics, and they represent a significant new investment in corrosion research. The initiative is described in greater detail in the Strategic Plan. The S&T WIPT will continue to focus on basic research topic proposals, especially associated with the Multidisciplinary University Research Initiative.

Quantify Current DoD Funding and Research Topics Addressing Corrosion Research topics and themes are summarized in other sections of this strategy. Current funding was summarized in the Strategic Plan and corrosion forums. Funding summaries for FY2005 and FY2006 were developed and incorporated into the Joint Program Plan and the Corrosion Preven-tion and Mitigation Strategic Plan.

Augment Project Reliance Inputs The S&T WIPT provided corrosion project summaries to be incorporated into the Joint Program Plan. These summaries will augment and specify the fiscal data in the Materials and Processes roadmaps.

Aid in Coordinating Research Efforts Among Multiple Services The S&T WIPT will continue to provide coordination personnel to service workshops and con-ferences and provide documentation and links on the DoD Corrosion Exchange website.

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Assist in Managing, Directing, and Coordinating Forthcoming Funding New and directed funding will continue to be a common agenda topic for the S&T WIPT. These projects will be incorporated into service summaries as they occur.

Provide a Cross-Component Corrosion Forum and Communication Group The S&T WIPT will continue to be a standing and formal part of CPC IPT forums and has estab-lished an interest group within the DoD Corrosion Exchange.

Provide a Central POC and Broker to Communicate Corrosion Needs The S&T WIPT has a central POC and broker in IPT forums to communicate corrosion needs and will continue to do so.

Establish Knowledge Base (Work with Communication and Outreach WIPT) The S&T WIPT is independently and jointly researching aspects of corrosion courses and training and populating the DoD Corrosion Exchange website with useful research information and links.

Develop Websites, Manuals, and Instructions for Corrosion Technologies The S&T WIPT is working with the DoD Corrosion Exchange and the Communications and Outreach WIPT to include S&T linkages on the DoD corrosion website. These linkages will connect interested private and public sector personnel and organizations with DoD Military Department and Agency S&T program solicitation and assistance sites.

Establish Mechanisms to Identify Problems and Convey Them to R&D In addition to existing service and agency methods (e.g., forums, workshops, and reviews) for identifying problems that S&T should consider addressing, the S&T WIPT has concluded that an exchange for problems and response interaction will be established within the S&T Interest Group area on the DoD Corrosion Exchange website.

Continually Review Technology Roadmap from Inception to Implementation This is an ongoing basic function of the S&T WIPT.

Identify Projects Linked to Common Technology Areas in Major Categories The current status of S&T projects is reviewed within the Corrosion Prevention and Mitigation Strategic Plan.

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Communications and Outreach WIPT Selected Item The Communications and Outreach WIPT has had many noteworthy accomplishments, including the estab-lishment and enhancement of the DoD Corrosion Exchange website (http://www.dodcorrosionexchange.org), the creation of a “Corrosion Ambassadors” presentation, and the design of a corrosion program display booth used effectively at various conferences and exhibitions. In addition, a significant new effort—the making of a DoD Corrosion Prevention and Control Outreach and Communication video—is underway and will be completed in time for the December 2007 DoD Tri-Service Corrosion Conference.

Another recent effort has been the development of a recurring (three times a year) corrosion publica-tion, CorrDefense, that focuses on news related to preserving DoD’s equipment and facility assets. The five editions that have been published have been widely acclaimed by both the public and private sec-tor corrosion communities. Topics generally focus on innovative methods to combat corrosion (i.e., success stories from the field that may be applicable to other activities) and information about the DoD program and its leadership. Table III-3 provides highlights of each edition, which can be found on the DoD Corrosion Exchange website.

Table III-3. CorrDefense Highlights

Fall 2005 Spring 2006 Summer 2006 Fall 2006 Spring 2007 • Pigging the Diesel

Pipeline Between the Landmark Red Hill Facility and Pearl Harbor

• Halvorsen Loader Proves Reliable for Aircrews and Support Troops (Cargo Loaders in Desert Undergo Corrosion Testing)

• Cargo Loader Named After World War II Candy Bomber

• Meet the Players Leading the DoD Corrosion policy and Oversight Initiative

• NAVAIR Spear-heads Corrosion Prevention on Prowler and Sea-hawk Fleets

• NAVSEA Looks to Composite tech-nology to Improve Warship Components

• Coast Guard Re-sponds to Hurri-cane Katrina: A Photo Essay

• Tri-Service Corrosion Confer-ence Broadens Program and Audience

• Rich hays Leads Communications and Outreach Team for DoD Corrosion Office

• Army Experts Brace Hostile Habitat to Detect Water Leaks

• Army Uses Smart Technology to Fight Corrosion at Fort Bragg

• Team Leader Pivotal in Improv-ing DoD Material Quality

• Expert Offers Tips on DoD Projection System

• Army Wages Corrosion War to Keep Helicopter Crews Safe

• Beating Corrosion is Vital at Patrick Air Force Base

• Saluting the Ca-reer of a DoD Cor-rosion Leader: A Profile of Dick Kinzie

• The Air Force Looks at the Benefits of Using CPCs on F-16 Black Boxes

• New Inspection Technology for Warships Enhances Safety and Lowers Costs

• University of Akron and Partners Lay Groundwork for New Corrosion Degree Programs

• DoD Meets with Australia’s Defense Science Technology Organization

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CorrDefense is a remarkable success story that provides tangible and useful information to the DoD corrosion community.

Metrics, Impact, and Sustainment WIPT Selected Item The MIS WIPT’s selected item—the cost-of-corrosion study—is detailed in Section IV.

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Section IV Status of Cost-of-Corrosion Baseline Study

Determining the cost of corrosion continues to be one of the Department’s linchpin requirements. The December 2003 and May 2005 Corrosion Reports to Congress stated:

To quantify improvement—an indispensable metric—an accepted baseline must be estab-lished. In addition, reliable corrosion cost estimates are necessary to identify areas that require aggressive action and to justify the expenditure of resources for prevention and mitigation strategy.1

DoD remains committed to this goal. An Air Force–funded cost-of-corrosion maintenance study was completed in 2005. In addition, the CPC IPT effort—which uses a DoD-wide methodology—is well underway.

Methodology The CPC IPT report, Proposed Method and Structure for Determining the Cost of Corrosion for the Department of Defense, details the approach being used to estimate the cost of corrosion. According to the report, cost is the most useful information for making decisions.

By determining the usefulness of the information relative to the decisions that would be made with the information, the report determines a priority for acquiring the different types of cost data. The priority ranking is provided in Table IV-1.

Table IV-1. Priority for Acquiring Corrosion Cost Information

Cost element Priority to acquire

Direct man-hours 1 Materials 1 Scrap and disposal 1 Facilities 2 Test equipment 2 Training 3 Research and development 3 Qualification 3

1 DoD Report to Congress, Long-Term Strategy to Reduce Corrosion and the Effects of Corrosion on the Mili-

tary Equipment and Infrastructure of the Department of Defense, December 2003, p. III-8.

IV-1

Each of these cost elements is mutually exclusive, and each can be classified as either preventive or corrective.

• Preventive costs involve steps taken to remove the causes of potential nonconformities or to make quality improvements. Preventive actions address potential problems; ones that haven’t yet occurred.

• Corrective costs are incurred if you try to remove the causes of an existing nonconform-ity or make quality improvements. Corrective actions address actual problems.

From a management standpoint, it is useful to determine the ratio between preventive costs and corrective costs. Over time, it is usually more expensive to fix a problem than it is to prevent one. But it is also possible to overspend on preventive measures. Classifying the cost elements into preventive and corrective categories helps decision makers find the proper balance between expenses and minimize the overall cost of corrosion.

The CPC IPT report concludes by proposing a standard data structure for capturing the cost of corrosion. The data structure is configured to provide visibility of corrosion costs at various lev-els of detail—from Service level to the weapon system and sub-system. The same data structure can be used to capture the cost of corrosion for facilities and infrastructure. A field for unique item identifiers is included in the data structure to allow for analysis of individual items of equipment or facilities. Figure IV-1 outlines the data structure in more detail.

Figure IV-1. Cost-of-Corrosion Data Structure (Army Example)

Data fields mandatory for all cost elements

A) TrainingB) Direct man-hours

I) Preventivea) Inspectionb) Other

II) Corrective

1) Performing activity

A) ArmyB) NavyC) Air ForceD) MarinesE) Coast GuardF) ContractorG) Other

2) Nature of costA) PreventiveB) Corrective

4) Type of cost element

C) Research and developmentD) QualificationE) Materials—list typeF) FacilitiesG) Test equipmentH) Scrap and disposal3) Actual cost incurred

Further detail – most useful cost elements (Army example)

Work Breakdown Structure (WBS) for COMBAT Equipment

WBS Code WBS Element

01 HULL/FRAME

Structure

Accommodations for subsystem

01A

01B

Etc.

WBS Sub-code WBS Sub-element

02 SUSPENSION/STEER

02A

02B

Wheels

Tracks

Etc.

WBS Sub-code WBS Sub-element

01C Towing and lifting fittings

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Using each Service’s existing work breakdown structure (WBS) to associate corrosion costs to as detailed a level as possible allows for better decision making and a focused application of re-sources to exploit potential improvement opportunities.2 For example, once the data are com-plete, the Services will have the opportunity to compare the average corrosion costs by weapon system, or by WBS within a weapon system family, to determine the highest cost contributors. Examining the ratio of corrective-to-preventive costs by weapon system can isolate potential op-portunities to shift this ratio and reduce the overall cost of corrosion for that weapon system. The Services will also have access to the data gathering methodology and the corrosion cost database to support further Service-unique analysis.

Once complete and accurate cost-of-corrosion information is obtained in the cost structure out-lined above, it will be useful for making corrosion mitigation decisions. The report highlights different types of decisions that could be made:

• To quantify the overall problem. This helps to determine the level of resources to apply to the corrosion issue, both in funding and manpower, and provides a performance metric to assess effectiveness of the overall strategy to reduce the effect of corrosion.

• To prioritize efforts by the highest cost contributors. This helps determine which corro-sion sources to attack first.

• To maximize the overall effectiveness of maintenance activities by classifying the costs as either preventive or corrective.

• To determine potential design deficiencies and feed this information back to the acquisi-tion community.

The ability to effectively make these types of decisions relies on the completeness and accuracy of the cost-of-corrosion information that is available.

Results Using the above methodology, a 2006 study estimated the annual cost of corrosion for Army ground vehicles and Navy ships. In ad-dition, an ongoing study is estimating the annual corrosion costs for DoD infrastructure, Marine Corps ground vehicles, and Army air-craft (fixed and rotary wing) and missiles. That study is scheduled to be completed in May 2007.

Army Ground Vehicle Corrosion Costs The 2006 study results estimated Army costs according to the three schemas for each of 520 different types of Army ground vehicles, which total more than 446,000 individual pieces of equipment (see Figure IV-2).

2 The WBS depicted in Figure IV-1 is part of the Army’s WBS used in their Operating and Support Manage-

ment Information System (OSMIS).

IV-3

Figure IV-2. Cost of Corrosion for Army Ground Vehicles (FY2004)

Percentage of totalCostVehicle Type 520

Percentage of totalCostVehicle Type 260

Parts direct corrosion costs

Structure direct corrosion costs

Preventive corrosion costs

Corrective corrosion costs

Outside normal reporting corrosion costs

Field-level maintenance costs

Depot maintenance corrosion costs

Percentage of totalCostVehicle Type 001

51.7%$653Parts direct corrosion costs

48.3%$611Structure direct corrosion costs

44.3%$528Preventive corrosion costs

55.7%$727Corrective corrosion costs

34.6%$700Outside normal reporting corrosion costs

51.8%$1,045Field-level maintenance costs

13.6%$274Depot maintenance corrosion costs

Percentage of total

Cost($ millions)Schema

The highest costs of corrosion occur during field-level maintenance, which incurs more than half the total corrosion cost for Army ground vehicles. This can be misleading, however, because the total expenditures for field-level maintenance for Army ground vehicles is much higher than the expenditures for depot maintenance of Army ground vehicles. More informative is the ratio of corrosion-related field-level maintenance costs to the total field-level maintenance costs for ground vehicles (15 percent) and the ratio of corrosion-related depot maintenance costs to total de-pot maintenance costs for ground vehicles (14 percent).

The significant costs identified as “outside normal reporting” are driven by the large population of vehicle operators and the corrosion maintenance they perform as operators or maintainers.

Navy Ships Corrosion Costs The cost-of-corrosion study determined Navy corrosion-related costs according to the three sche-mas for each of the Navy’s 256 ships (see Figure IV-3).

IV-4

Figure IV-3. Cost of Corrosion for Navy Ships (FY2004)

Percentage of totalCostShip 256

Percentage of totalCostShip 128

Parts direct corrosion costs

Structure direct corrosion costs

Preventive corrosion costs

Corrective corrosion costs

Outside normal reporting corrosion costs

Field-level maintenance costs

Depot maintenance corrosion costs

Percentage of totalCostShip 001

50.7%$650Parts direct corrosion costs

49.3%$634Structure direct corrosion costs

52.9%$1,040Preventive corrosion costs

47.1%$927Corrective corrosion costs

12.9%$314Outside normal reporting corrosion costs

31.9%$779Field-level maintenance costs

55.2%$1,345Depot maintenance corrosion costs

Percentage of total

Cost($ millions)Schema

Unlike the Army, the largest cost of corrosion for Navy ships occurs during the performance of depot maintenance. Corrosion-related depot maintenance costs represent more than half of the total corrosion costs for Navy ships. Corrosion costs also represent a relatively high percentage of total maintenance costs for Navy ships—28 percent of the total depot maintenance costs, and 13 percent of total field-level maintenance costs.

Corrosion Cost Focus Areas

Army Although the corrosion costs that are attributable to removable parts slightly exceed corrosion costs associated with the body frame or structure of Army ground vehicles, the situation is dras-tically different when comparing these corrosion costs as a percentage of maintenance costs. Structural corrosion costs are 25 percent of structural maintenance costs, whereas corrosion costs are only 13 percent of the maintenance attributable to removable parts. This is important to note because there is more of an opportunity to find common preventive and corrective corrosion so-lutions that affect the body frame or structure of ground vehicles than there are common solu-tions that affect the hundreds of thousands of different removable vehicle parts.

The study stratified corrosion costs for Army ground vehicles by total cost and cost per vehicle. Four Army ground vehicles were among the top 20 in both total corrosion cost and corrosion cost per vehicle. These vehicles, which are listed in Table IV-2, are candidates for further focus.

IV-5

Table IV-2. Army Ground Vehicles with the Highest Combined Average Corrosion Cost per Vehicle and Total Corrosion Cost

Description

Average corrosion cost

per vehicle Rank in the

top 20 average Total

corrosion cost Rank in the top 20 total

Tank, combat—120mm M1A1 $25,151 3 $133,549,785 2

Tank, combat—120mm M1A2 $16,668 6 $22,335,378 17

Truck, cargo—tactical $12,982 11 $23,159,719 16

Truck, utility—armored TOW carrier $12,465 12 $23,796,003 15

Navy Of the five categories of Navy ships in this study (aircraft carriers, amphibious, surface warfare, submarines, and other ships), amphibious ships have the highest corrosion costs, particularly at the depot level of maintenance. More than 50 percent of total depot maintenance costs for amphibious ships are corrosion-related.

For corrosion costs that can be assigned to an expanded ships work breakdown structure (ESWBS), more than 42 percent are attributable to the top five ESWBS areas. Because there are more than 550 ESWBS codes with associated corrosion costs, this is a significant concentration of corrosion costs. These five ESWBS codes are listed in Table IV-3.

Table IV-3. Navy Ships ESWBS Codes with Highest Contribution to Corrosion Cost

ESWBS Description Corrosion cost Percentage of total

corrosion cost

123 Trucks and enclosures $204 million 10.7%

992 Bilge cleaning and gas freeing $182 million 9.6%

631 Painting $166 million 8.7%

863 Dry-docking and undocking $149 million 7.8%

634 Deck covering $103 million 5.4% Total $804 million 42.2%

All others $1,098 million 57.8%

Schedule The DoD Corrosion Prevention and Control IPT scheduled the different cost-of-corrosion studies using the standard cost structure outlined above. The schedule for these studies is presented in Table IV-4.

IV-6

Table IV-4. Schedule of Cost-of-Corrosion Studies

Year Study area Corrosion

costs

2004–2005 Air Force (USAF funded, USAF methodology) $1.5 billion 2005–2006 Army ground vehicles $2.0 billion

Navy ships $2.4 billion 2006–2007 DoD facilities $1.8 billiona

Army aviation $1.6 billiona USMC ground vehicles $0.7 billiona

2007–2008 Navy aviation, USMC aviation, and Coast Guard aviation and ships 2008–2009 Air Force aviation, Navy ships and Army ground vehicles 2009–2010 Repeat FY2006/FY2007 2010–2011 Repeat FY2007/FY2008

a Preliminary estimate.

The incremental approach and schedule outlined above will enable DoD to establish an accepted cost-of-corrosion baseline. In addition, as soon as reliable corrosion cost estimates are available, they are being used to identify areas that require aggressive action and to prioritize resources for prevention and mitigation.

Finally, repeating the studies every 3 years will provide trending information that can be used to measure progress toward the Department’s goal of preventing or mitigating corrosion. Also, a 3-year study cycle will provide “refreshed data” to assist the Services in targeting areas that are most in need of resources.

IV-7

IV-8 IV-8

Section V Corrosion Reduction Projects

A total of 214 corrosion-related projects were submitted by the Services for approval during the 3 years between 2004 and 2006 (for use of FY2005, FY2006, and FY2007 funding). Of the sub-missions, 82 projects (38 percent of the total submitted) were approved based upon established criteria:

• Joint emphasis

• Less than 2 year performance period

• New technology

• Matching/complementary funds

• Return on investment (ROI) calculation based on Office of Management and Budget (OMB) guidelines.1

To manage the investment of resources, the DoD Corrosion Executive established a project analysis cell that reports to the Special Assistant for Corrosion Control and Oversight and tracks the technical and financial status of each project.

Projects Funded in FY2005 Twenty-four of the 28 approved FY2005 projects were designated as joint projects, meaning they were applicable to two or more Services. In addition, other projects were considered synergistic, in that at least one other Service was awaiting the results to determine potential applicability. Joint projects received more than 90 percent of the combined Service and OSD funding.

The ROI for the FY2005 approved projects, based on OMB guidelines, ranged from 2:1 to 120:1, with an average of 55:1; but the full ROI will not be realized until many years after a project has been completed. For example, the composite boxes project (N-W-208) are being installed on nu-clear aircraft carriers during their scheduled maintenance availability, so the full ROI will not be realized until all vessels have been enhanced.

Table V-1 lists the 28 approved projects funded during FY2005 and includes the lead Service, whether the project is a joint project, as well as the amount of OSD and Service funding.

1 Project selection and management information is detailed in DoD’s Corrosion Prevention and Mitigation

Strategic Plan, November 2004, Appendix D.

V-1

Table V-1. FY2005 Approved Corrosion Projects and Planned Funding

Project Joint

project Lead

service Index no.

Service funding

OSD funding Page

Weapon systems or equipment CPC implementation on C-5 aircraft USAF AF-W-101 $300,000 $260,000 B-1 Aircraft electrical connector corrosion inhibitor implementation

USAF AF-W-107 $114,000 $500,000 B-1

Rapid cure aircraft coating (roller/brush/aerosol) USAF AF-W-117 $100,000 $178,000 B-1

Using rapid cure coatings for well deck preservation

Navy N-W-201 $250,000 $700,000 B-1

Wireless corrosion sensor for surface ships Navy N-W-203 $400,000 $570,000 B-2 Composite electrical boxes Navy N-W-208 $110,000 $230,000 B-2

USMC automated vehicle washdown system USMC N-W-211 – $257,000 B-2

On the lot dehumidified storage plan USMC N-W-212 – $250,000 B-2

Improved coatings for magnesium components Navy N-W-214 $400,000 $420,000 B-3

Av-DEC sealants for conductive gaskets and floorboard implementation

Navy N-W-215 $3,832,000 $2,891,000 B-3

Improved corrosion prevention materials and processes

Navy N-W-216 $220,000 $470,000 B-3

Clear water rinse system Army AR-W-303 $3,000,000 $1,704,000 B-4

AMCOM-NAVAIR corrosion partnership Army AR-W-305 $400,000 $650,000 B-4

Army corrosion control kit Army AR-W-309 $2,066,000 $148,000 B-4

Facilities and infrastructure Installation of supervisory control acquisition data automation for cathodic systems

USAF AF-F-116 $468,000 $435,000 B-5

Self-prime coating for splash zone steel Navy N-F-221 – $749,000 B-5

Internal pipeline corrosion inspection Red Hill Tunnel fuel lines

Navy N-F-222 $1,450,000 $1,445,000 B-5

Ambient temperature cured coatings (ADSIL) Navy N-F-223 $300,000 $300,000 B-6

Life jacket Navy N-F-229 $500,000 $500,000 B-6

Measuring the rate and effect of corrosion damage on DoD equipment

Army AR-F-311 $427,000 $500,000 B-6

Leak detection for pipes Army AR-F-313 $250,000 $258,000 B-6

Non-hazardous corrosion inhibitors/SMART control systems

Army AR-F-314 $1,300,000 $1,256,000 B-7

Pipe corrosion sensors Army AR-F-317 $100,000 $150,000 B-7

Ice-free cathodic protection systems for water storage tank

Army AR-F-318 $500,000 $490,000 B-7

Corrosion-resistant materials for waste and wastewater treatment

Army AR-F-319 $530,000 $513,000 B-8

Surface-tolerant coatings for aircraft hangars, flight control towers, and other assets

Army AR-F-320 $420,000 $303,000 B-8

Remote monitoring of cathodic protection systems

Army AR-F-321 $490,000 $596,000 B-8

Cathodic protection of hot water storage tanks using ceramics

Army AR-F-322 $1,100,000 $500,000 B-9

V-2

Projects Funded in FY2006 Twenty-three of the 29 approved FY2006 projects are joint projects, meaning they were applica-ble to two or more Services. In addition, the majority of the projects are considered synergistic, in that at least one other Service is awaiting the results to determine potential applicability.

The ROI for the approved FY2006 projects, based on OMB guidelines, ranged from 3:1 to 300:1, with an average of 42:1; but the full ROI may not be realized until many years after a project has been completed. For example, the enhanced self-priming topcoat project (WNA01), if success-ful, would be applied to ships during their scheduled maintenance availability, so the full ROI will not be realized until all vessels have been enhanced.

Table V-2 lists the 29 approved FY2006 projects.

Table V-2. FY2006 Approved Corrosion Projects and Planned Funding

Project Joint

project Lead

service Index no.

Service funding

OSD funding Page

Weapon systems or equipment PEO ASMD Patriot Missile cable connector protective covers

Army WAR07 $200,000 $500,000 C-1

Demonstration and validation of quasi-crystalline coatings

Army WAR12 $235,000 $405,000 C-1

Enhanced self-priming topcoat Navy WNA01 $70,000 $100,000 C-1

Mil-Spec primers and topcoats in new 1 & 2 component aerosol delivery cans

Navy WNA03 $50,000 $140,000 C-2

Aircraft shelters Navy WNA05 $660,000 $250,000 C-2

Corrosion Prevention Compounds (CPCs) Navy WNA19 $105,000 $110,000 C-2

Corrosion detection algorithm for ship’s topside coatings

Navy WNS11 $125,000 $500,000 C-2

Self-inspecting coatings Navy WNS18 $100,000 $425,000 C-3

Magnesium rich primer for chrome free aircraft coating systems

USAF WAF01 $150,000 $225,000 C-3

Prevention of sand induced circuit card/electrical interconnect system corrosion

USAF WAF02 $100,000 $500,000 C-3

Wash/rinse program USAF WAF03 $75,000 $265,000 C-4

Cumulative Environmental Exposure Sensors (CEES) for C-130 fleet management

USAF WAF04 $130,000 $500,000 C-4

Application of rapid cure aircraft coating paint USAF WAF07 $50,000 $75,000 C-5

Develop and qualify DIEGME resistant fuel tank coatings

USAF WAF09 $1,050,000 $140,000 C-5

V-3

Table V-2. FY2006 Approved Corrosion Projects and Planned Funding

Project Joint

project Lead

service Index no.

Service funding

OSD funding Page

Facilities and infrastructure Electro-osmotic pulse technology Army FAR01 $500,000 $500,000 C-6

Smart-fluorescent and self healing coatings Army FAR02 $500,000 $500,000 C-6

Green water treatment Army FAR03 $1,000,000 $500,000 C-7

Remote corrosion sensors for detection—mission essential structures

Army FAR04 $440,000 $450,000 C-7

Innovative thermal barrier coatings Army FAR11 $290,000 $350,000 C-7

Coating system for CP and fire resistance for metal structures

Army FAR13 $490,000 $500,000 C-8

Development of corrosion indices and life cycle protection

Army FAR15 $290,000 $200,000 C-8

CP of rebar in critical facilities Army FAR16 $490,000 $490,000 C-8

Ceramic anode upgrades Army FAR20 $500,000 $500,000 C-9

Sustainable materials replacement Army FAR21 $500,000 $500,000 C-9

CP utilizing IR drop free sensors Navy FNV01 $260,000 $255,000 C-9

Modeling advanced waterfront metallic materiel corrosion and protection

Navy FNV04 $270,000 $200,000 C-10

Wire rope corrosion for guyed antenna towers Navy FNV06 $250,000 $250,000 C-10

Solar powered CPS systems Navy FNV07 $75,000 $75,000 C-10

Ambient temperature cured coatings Navy FNV13 $400,000 $400,000 C-11

Projects Funded in FY2007 Twenty-one of the 25 approved FY2007 projects were designated as joint projects, meaning they were applicable to two or more Services. In addition, other projects were considered synergistic, in that at least one other Service was awaiting the results to determine potential applicability. Joint projects received nearly 87 percent of the combined Service and OSD funding.

The ROI for the approved FY2007 projects, based on OMB guidelines, ranged from 3:1 to 66:1, with an average of 52:1; but the full ROI may not be realized until many years after a project has been completed. For example, the monitoring system for ship ballast tanks (project W07NS08) is being installed on ships during their scheduled maintenance availability and when work within a ballast tank is already scheduled, so the full ROI will not be realized until all ballast tanks have been enhanced.

Table V-3 lists the 25 approved projects, and includes the lead Service, whether the project is a joint project, as well as the amount of planned OSD and Service funding.

V-4

Table V-3. FY2007 Approved Corrosion Projects and Planned Funding

Project Joint

project Lead

service Index no.

Service funding

OSD funding Page

Weapon systems or equipment Service life prediction tool Army W07AR04 $175,000 $425,000 D-1

Antimicrobial mildew growth/bio-corrosion Army W07AR06 $488,000 $138,000 D-1

Advanced corrosion prevention compounds Navy W07NA03 $75,000 $90,000 D-2

Enhanced self-priming topcoat Navy W07NA04 $96,000 $100,000 D-2

Quality assurance tools Navy W07NS01 $300,000 $350,000 D-2

Composite connectors and conduits Navy W07NS02 $215,000 $215,000 D-3

Disposable dispensing paint cartridges Navy W07NS05 $50,000 $200,000 D-3 Induction heating coatings removal Navy W07NS07 $500,000 $485,000 D-4

Tank monitoring system for ballast tanks Navy W07NS08 $100,000 $500,000 D-4 Fastener materials USMC W07MC02 $70,000 $200,000 D-4

Flexible primer USAF W07AF04 $100,000 $325,000 D-5

Sand erosion test USAF W07AF06 $168,000 $395,000 D-5 Qualification and integration of Av-DEC antenna gaskets on C-17 aircraft

USAF W07AF08 $920,000 $143,000 D-6

Facilities and infrastructure Corrosion resistant non-metallic materials for HDS piping

Army F07AR01 $500,000 $450,000 D-7

Corrosion/degradation monitoring technology for FRP composites

Army F07AR03 $490,000 $450,000 D-7

Corrosion detection and management (potable water)

Army F07AR05 $500,000 $300,000 D-8

Advanced acoustic leak detection Army F07AR07 $500,000 $445,000 D-8

Rehabilitation of metal roofing Army F07AR08 $500,000 $445,000 D-9

Long-life thermal spray coatings for metal structures

Army F07AR10 $400,000 $380,000 D-9

Advanced corrosion resistant steel for fire sup-pression pipeline rehab

Army F07AR15 $500,000 $340,000 D-10

Insitu pipe coating technology for fire suppres-sion system

Army F07AR17 $460,000 $440,000 D-10

Inherently conductive additives for reducing zinc dust content

Army F07AR19 $500,000 $450,000 D-11

Concrete corrosion inhibitors Navy F07NV03 $350,000 $350,000 D-11

Navy remote monitoring unit Navy F07NV04 $145,000 $145,000 D-11

Stainless steel reinforcing for concrete structures Navy F07NV07 $400,000 $325,000 D-12

V-5

V-6 V-6

Section VI Detailed Results of Selected FY2005 Projects

The previous section identified the 28 corrosion projects funded in FY2005, and Appendix B in-cludes summaries of each project’s purpose, technology, application and benefits. This section highlights, in greater detail, the results from a representative sample of those projects. Selected projects are from each of the Services for both equipment and infrastructure.1

• Army facilities: Leak Detection for Potable Water Lines at Fort Hood (AR-F-313)

• Navy facilities: Red Hill Tunnel Fuel Lines (N-F-222)

• Air Force facilities: Supervisory Control and Data Automation for Cathodic Protection (AF-F-116)

• Army equipment: AMCOM-NAVAIR Corrosion Partnership (AR-W-305)

• Navy (NAVAIR) equipment: Av-DEC Sealants for Conductive Gaskets (N-W-215)

• Navy (NAVSEA) equipment: Composite Electrical Boxes (N-W-208)

• Air Force equipment: Aircraft Electrical Connector Inhibitor (AF-W-107)

• Marine Corps equipment: Automated Vehicle Wash-Down System (N-W-211).

Army Facilities: Leak Detection for Potable Water Lines at Fort Hood Thousands of miles of direct-buried water distribution lines are subject to severe corrosion at al-most all U.S. Army installations. Leakage of storage tanks and piping systems has been identi-fied as a mission critical problem. To demonstrate acoustics-based leak-detection technology, permanent acoustic leak-monitoring sensors were installed on potable water lines at Fort Hood, Killeen, TX, from April 24 to May 31, 2005.

As a result of the work, 25 permanent acoustic leak detection sensors now monitor about 7 miles of potable water lines in remote, little traveled areas, where a water leak would not likely be dis-covered for a long time. To retrieve the leak status from the 25 sensors, one method is to use a special radio receiver that periodically can be driven past the sensors; the other is to use a central computer equipped with cellular telephone modems that retrieve the data automatically.

During 18 months of operation at Fort Hood, the leak sensors discovered two leaks. One leak showed surface water and was located near a fire hydrant that had leaked in the past, been repaired, and re-developed a leak after the permanent leak monitoring system was operational.

The second leak showed absolutely no surface water whatsoever and was located in a very secure area. This leak was initially found after examining the permanent leak sensor’s database, and was later verified by Carlyle Consulting using a cross-correlation leak location instrument during the

1 Information for this section was extracted from completed project reports.

VI-1

final project inspection by OSD, the Army Assistant Chief of Staff for Installation Management (ACSIM), the Engineer Research and Development Center’s (ERDC’s) Construction Engineering Research Center (CERL), and Fort Hood personnel.

Figure VI-1 shows 10 PermaLog sensors and their drive-by data retrieval unit. Each PermaLog is about the size of a 12 ounce can of soda, and has a magnet on the bottom that allows it both to hold tightly to the pipeline and to acoustically couple any tiny leak sounds propagating through the pipe into the PermaLog.

Figure VI-1. Ten PermaLog Leak Sensors with a Patroller (Drive-by) Data Retrieval Unit

Specific project conclusions were as follows:

1. The PermaLog leak sensors installed at West Fort Hood proved they can detect water leaks, including leaks where water never rises to the surface. Two separate leaks were discovered, including one that was totally hidden from view and probably would never have been found without the use of the PermaLog system.

2. A detailed procedure has been developed for determining suitable sensor locations, find-ing pipelines, and installing sensor housings that will not interfere with data collection.

3. Two separate methods of retrieving the leak data were developed, as were methods for analyzing the data to find leaks.

4. A number of lessons were learned about some installation and operation pitfalls that will be beneficial to others that undertake the installation of permanent sensors on pipelines at other Army installations.

5. Payback periods for purchasing the necessary leak sensor equipment, according to civil-ian water utility experience, are approximately 5 years.

VI-2

Navy Facilities: Red Hill Tunnel Fuel Lines The Red Hill Fuel Storage facility located at Pearl Harbor, HI, provides the majority of the fuel for the entire Pacific Fleet. The facility was built into Red Hill during World War II and has been in con-tinuous service since. The 20 Red Hill storage tanks are connected to Pearl Harbor by pipelines that stretch more than 3 miles through a tunnel deep inside the Red Hill facility (Figure VI-2). The tanks store approximately 252 million gallons of fuel, which are delivered to ships at Pearl Harbor.

Figure VI-2. Red Hill Underground Fuel Facility

DoD will typically conduct an inline inspection (ILI) of strategic and high-risk pipelines like Red Hill; however, logistical complications and required modifications to conduct an inline in-spection on the Red Hill pipeline made this cost prohibitive. Spot-checking and lower resolution external methods have been used at accessible points since 1942 to ensure the line continues to provide fuel to the fleet. However, there was continued concern about the integrity of the pipe in areas where spot checks were not yet or could not be conducted.

The project provided a thorough inline inspection of every inch of the 32-inch diesel pipeline from Red Hill to the pump house at Pearl Harbor using the latest inline inspection ultrasonic technology. The project included 10 discrete phases:

• Integrity assessment method investigation • Planning

• Fabrication of components • Mobilization

• Installation of components • Cleaning

• In-line inspection • Long-range guided wave inspection

• Demobilization • Analysis.

VI-3

During the inspection, a critical leak was discovered that likely would have resulted in a catastrophic failure if left undetected. Overall, the inspection provided a complete, intensive assessment of the level of corrosion damage to the pipeline. In total, 375 anomalies and features were located:

• 27 incidences of external metal loss

• 1 incidence of internal metal loss

• 228 laminations

• 63 dents

• 4 repair sleeves

• 21 sections with external circumferential welds (walls)

• 4 off-takes

• 26 pipe supports

• 1 possible construction feature.

Figure VI-3. Red Hill Tunnel Inspection

This project’s results are allowing the Navy to identify and repair trouble spots before a critical failure, and to facilitate long range planning of logistical fuel supply for the Pacific Theatre. Spe-cifically, four separate projects are planned to implement the results and recommendations of the integrity assessment for the Red Hill pipelines:

• Repair the corroded areas of the 32 in. pipelines by replacing pipe segments. In addition, replace portions of the 16 in. and 18 in. pipelines that are in the same location of the ma-jor corroded areas of the 32 in. pipeline. The corrosion is due to water leaking from the top of the tunnel. Coat areas of the 32 in., 16 in., and 18 in. pipelines that are showing signs of major corrosion. The contract to perform this work was awarded in 2006.

• Perform a coating survey for the remaining pipeline in the tunnel. This coating survey should indicate the portions of the pipelines that should be coated over a 3–5 year pro-gram. At the end of the program, all of the pipelines will be recoated.

VI-4

• Develop and execute a pipeline integrity program for the pipelines in the tunnel. This in-tegrity program will include conducting testing and analysis to determine the normal and maximum operating pressures of the pipelines. The next pigging project will be sched-uled following the repairs and after determining the actual operating pressures of the pipeline. This will be based on the formulas provided in API 570.

• Perform a tunnel integrity survey to determine the cause of the water dripping into the tunnel, and repair the cause of the water infiltration.

Based on the success of the demonstration project, this technology will be considered for use in conducting future condition and integrity assessments of other DoD petroleum, oil, and lubri-cants (POL) pipelines.

Air Force Facilities: Supervisory Control and Data Automation for Cathodic Protection Supervisory Control and Data Automation (SCADA) generally refers to a large-scale, distributed measurement (and control) system. SCADA systems are used to monitor or control water supply sys-tems; gas and oil pipelines; and electric power generation, transmission, and distribution systems.

Corrosion-related SCADA enhancements at federal installations historically have involved per-formance solely by a contractor with a proprietary solution. These proprietary efforts routinely increased the costs associated for sustainment, were not compatible with other DoD systems, and were not generally built within an open architecture. The objective of this project was to evaluate the feasibility for the installation of a non-proprietary SCADA Cathodic Protection (CP) system throughout the DoD. Specific tasks included the installation of new and proven technology, de-velopment of recommendations, identification of lessons learned, documentation of expendi-tures, and ROI calculation.

The overall purpose was to remotely monitor, through SCADA, cathodic protection system op-erations at a test location—Robins AFB, GA—using hardwire and radio unit instrumentation to transmit real-time voltage and current readings back to central monitoring.

The SCADA enhancements, which were deployed utilizing COTS (commercial off-the-shelf) web-enabled cathodic protection solutions, resulted in the leveraging of investments and mini-mizing resources while enhancing the effectiveness and efficiency of data retrieval. The technol-ogy was in compliance with current DoD computer infrastructure security policies and protocols. The digging permit process, a good example of the effects on operational logistics, was signifi-cantly improved by SCADA implementation.

The test provided accurate and consistent data that was essential to properly assess constraints and reduce expenditures and resources. Further, data integration capabilities will provide deci-sion-making information that is expected to minimize damage to utilities and readily identify the source of the corrosion defect.

Installation of enhanced COTS SCADA CP systems across the Department has the potential to significantly reduce costs and increase the operational readiness infrastructure assets.

VI-5

VI-6

Army Equipment: AMCOM-NAVAIR Corrosion Partnership The AMCOM/NAVAIR Corrosion Partnership Project has established synergism and mutual benefits by combining efforts of the two services. Development of corrosion prevention and con-trol procedures and technologies were shared with the joint community for adoption. The AMCOM-NAVAIR Corrosion Partnership provided direct support to the Aviation RESET2 Pro-gram Management Office (PMO), enhanced Navy and Army aviation participation in the Joint Council on Aging Aircraft Corrosion Steering Group (JCAA-CSG), and development of Joint DoD Corrosion Projects for Army Aviation and Naval Air Systems Command.

Specific tasks associated with this project included visits to RESET sites to perform corrosion assessments of aircraft, identification of corrosion technology solutions, and corrosion technol-ogy training for approximately 25 aviation RESET sites worldwide. Examples of some of the technology solutions are shown in Figures VI-4 through VI-7.

Figure VI-4. High Speed Bristle Discs

Figure VI-5. Qualifying Aerosol Paints

Figure VI-6. Corrosion Preventative Technologies for Avionics

2 The U.S. Army Material Command defines its RESET program as “extraordinary actions to restore combat,

combat support and combat service support units to combat capability commensurate with mission requirements and availability of resources” (http://www.amc.army.mil/g3/major_programs/resetdesc.htm, accessed January 25, 2007).

MIL-PRF-85285 MIL-PRF-23377 MIL-PRF-23377N

Figure VI-7. Magnesium Coatings

The AMCOM Corrosion Program Office and NAVAIR made several joint visits to major Army aviation RESET locations and Navy depots to assess and determine corrosion found on helicop-ters returning from Operation Enduring Freedom (OEF) and Operation Iraqi Freedom (OIF). Many of these aircraft were found to be in accelerated states of corrosion due to the operating environments in Afghanistan and Iraq. The high operations tempo (OPTEMPO), combined with the inability to accomplish corrosion preventive maintenance during deployment, severely af-fected aircraft operational readiness by promoting corrosion and resulting in increased corrosion maintenance requirements during RESET. One of the factors discovered during the partnership assessments was the lack of new corrosion technologies at RESET sites.

The AMCOM-NAVAIR Corrosion Partnership Team was able to insert and implement the most current technologies to improve corrosion prevention and control on helicopters returning to Southwest Asia. However, helicopters returning from these corrosive environments will need all the leverage the AMCOM-NAVAIR Corrosion Partnership can provide to remain viable national assets for future conflicts.

Navy (NAVAIR) Equipment: Av-DEC Sealants for Conductive Gaskets The corrosion of electrical interfaces for antennas, static wicks, and other aircraft hardware is common because of the competing need to maintain electrical continuity and low contact resis-tance for proper device function and to maintain protection from the operating environment. As a result, effective corrosion preventive materials, like polysulfide sealants and epoxy primers, can-not be used at the interface of these components, where they would be most effective. For exam-ple, a typical antenna installation relies only on a conversion coating on the aluminum aircraft surface and perimeter seal around the interface of the aircraft and antenna base. Figure VI-8 de-picts the aircraft’s surface after the antenna removal. Figure VI-9 and Figure VI-10 show anten-nas that were removed without and with the Av-DEC gasket installed. The antenna depicted in Figure VI-9 was condemned due to corrosion at a cost of $5,000.

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Figure VI-8. Surface of Aircraft after Antenna Removal

Figure VI-9. Communications Antenna after Removal (without Av-DEC Gasket)

Figure VI-10. Communications Antenna after Removal (with Av-DEC Gasket)

A similar problem is prevalent with aircraft floorboards, where the use of polysulfide sealants leads to excess material damage when panels are removed. In addition, once the sealants are damaged in service, corrosive species easily penetrate floorboards and damage the underlying structure.

The Department of Defense and Coast Guard implemented a new polyurethane gasket material produced by Av-DEC for these applications. The goal is to eliminate corrosion and allow fast and easy removal of components for inspection or repair.

For conductive applications, the polyurethane has an embedded aluminum mesh that compresses during installation to yield proper electrical contact. These gaskets are typically supplied in pre-cut

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form. For non-conductive applications like floorboards, the gasket is supplied in rolls and cut to the desired width.

Av-DEC gaskets have proven the potential to reduce corrosion and maintenance costs on all types of DoD and Coast Guard aircraft. They provide an array of improvements, such as im-proved communications and electrical performance, increased time-on-wing, reduced component scrap rate, and reduced maintenance man-hours. The evaluation of their full value will continue in the future by completing cost-to-benefit analyses at regular intervals. The benefits of the gas-kets are expected to increase as users validate current inspection intervals and consider longer ones. The full potential benefit will be achieved for platforms that can bridge depot-level main-tenance, thus eliminating inspections in the fleet. This would reduce inspections by at least 75 percent during the aircraft lifetime for aircraft that have gaskets installed during manufacture, a significant improvement over previously required procedures.

Navy (NAVSEA) Equipment: Composite Electrical Boxes Current metallic boxes/housings for electrical equipment, indicator lights and connectors used on Navy ships, Military Sealift Command (MSC) vessels, and Army watercraft require frequent re-painting and represent one of the most significant sources of corrosion-related topside mainte-nance tasks for a ship’s force. The boxes corrode and require repainting and repair every 3 years, and half of the boxes are replaced every 6 years. In addition, because the boxes are typically made of brass, they cause galvanic corrosion of the ship’s steel superstructure, resulting in more re-preservation work for the ship’s force, which must repair the corrosion damage to the boxes because they are an integral part of critical ship oper-ating or force-protection systems. Box failures can cause the ship’s force to “jury-rig” extension cords and relays to accomplish critical functions, such as communication operating commands to force protec-tion stations or ensuring anti-swimmer security lights are functional. The large number of boxes on Navy and MSC ships and Army watercraft compound the maintenance costs and potential operation degrada-tion. For example, there are 477 topside boxes on an aircraft carrier; repairing, repainting, and rewiring these boxes on a carrier costs the Navy nearly $1.2 million over 10 years.

Figure VI-11. Metallic Electrical Box

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This project leveraged composite box technology devel-oped by the Air Force for use on cargo aircraft. The pro-ject expanded the Air Force’s effort by developing cost-effective, corrosion-resistant, fire retardant, shock-qualified, electromagnetic interference/electromagnetic pulse (EMI/EMP)–hardened composite boxes that can be used as direct replacements for the metallic boxes currently on ships. By using composite electrical boxes that are inherently corrosion resistant and that use stainless steel standoff studs to prevent galvanic corrosion of the superstructure, an entire category of topside maintenance and repair can be eliminated.

Figure VI-12. Composite Electrical Box

The boxes are fabricated from grey Ultem resin with 316 stainless steel hardware that does not corrode, does not need painting, does not degrade in the sun, and re-quires little, if any, maintenance for the life of the ship. The composite boxes incorporate durable, spring-loaded covers that are easy for sailors to use and that automatically close; thus preventing the corrosion of the electrical connections. Finally, the boxes are installed as a system (on each vessel) using 316 shoulder studs that are welded to the steel hull and prevent structure corrosion.

Table VI-1 depicts the number of ships that could be enhanced by composite electrical boxes.

Table VI-1. Number of Electrical Boxes by Fleet

Ship type Number of boxes Number of ships Total electrical boxes

CVN, CV 477 12 5,724 LHD, LHA, LSD, LPD 230 36 8,280 Combatant & other 125 190 23,750 MSC 60 116 6,960 Army 29 166 4,814

Total 921 520 49,528 Notes: CV: carrier vessel; CVN: carrier vessel nuclear; LHA: Amphibious assault ship (general purpose); LHD:

Amphibious assault ship (multi-purpose); LPD: Amphibious transport/landing dock; LSD: Dock landing ship.

Extrapolation of cost savings by use of composite boxes over 30 years is projected to be $353 million. The financial benefits, plus the increased readiness of the vessels’ electrical sys-tems, are significant and validate the value of this project.

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Air Force Equipment: Aircraft Electrical Connector Inhibitor The requirement for this project began with an investigation of an F-16 engine flameout, which revealed corrosion in the electrical connector of the aircraft main fuel shutoff valve (MFSOV) actuator connector. Investigators recognized that moisture and corrosion could allow a short cir-cuit from the “open pin” to the “close pin;” thus driving the valve to close inadvertently. An ini-tial study that examined the circuitry and failed parts from MFSOV actuators concluded that a high percentage are likely in partial failure mode at all times due to fretting corrosion of the pins contacting gold sockets in the electrical connector.

An initial study was conducted to evaluate the effectiveness of existing corrosion preventive compounds (CPCs) in preventing corrosion, especially in electrical connectors. The results were surprising, in that

• at least half of the commercial products that were touted as CPCs and used on DoD equipment actually accelerated corrosion in some tests, and

• even hard gold (Au/Au) plated connector contacts without CPCs corroded enough within 6 months in a benign environment to cause intermittent conductance failures.

A follow-on study focused on identifying and quantifying the effects of preventing corrosion in electrical connectors using the best of the CPCs in the previous tests. The 3-year test, using the F-16 aircraft as a test bed, substantiated all of the expected benefits to an extent greater than anticipated.

The next and most important step is the transition from testing to full implementation with the Air Force’s 1,400 F-16 aircraft. Thus far, the Fuel System Job Guide (JG) instructions for the MFSOV actuator installation and checkout have been revised to include a requirement to treat the actuator’s electrical connector with a corrosion prevention compound. Additional required steps, and the focus of this project, included

• educating and encouraging a “buy in” from all F-16 users (to counter the perception that aircraft line replaceable unit (LRU) failures are normal with the realization that many failures can be prevented with the use of corrosion prevention compounds);

• ensuring each F-16 field unit loads the correct corrosion prevention compound national stock number (NSN) into its supply system;

• researching corrosion applicable DoD and Air Force manuals, standards, handbooks, and technical orders (TOs) to determine what new instructions were required to fully implement the technology and mandate the corrosion prevention compound treatment when required;

• editing the TOs with the new instructions on a precedence basis so each TO change is as-signed an appropriate release time;

• visiting each Air Force F-16 base to train maintenance managers and technicians; and

• monitoring the mission capable status and maintenance actions on each aircraft to deter-mine the statistical effects of the connector corrosion prevention compound treatment.

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Each of the above actions is ongoing, and the preliminary results appear promising. The effort is at the stage when there are likely sufficient time/flight hours after CPC application to begin the analysis of results. This work was started on F-16 aircraft from Shaw Air Force Base (AFB). Data was ob-tained by 5 digit work unit codes (WUCs) for the group of tail numbered aircraft reported to be treated. Similar data was obtained from a second group of aircraft at Shaw AFB that were not treated. Further, data for the same LRUs/WUCs were obtained for the F-16C and F-16D aircraft from each Air Force major command (MAJCOM). All results were analyzed on a per-flight-hour basis, as in earlier analyses.

The first results are shown in Figure VI-13. In this case, the data displayed pertains to reported removals of LRUs. Specifically, the data represents the sum of all relevant LRUs. Subsequent reporting will focus on results for individual LRUs.

Figure VI-13. Effects of LRU Lubrication (F-16 Aircraft from Shaw AFB)

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Months After 1 January, 2006

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The data appears to show a positive effect of lubrication when the two groups of Shaw AFB F-16 aircraft were compared. Data is still being gathered from Shaw AFB as well from all other USAF F-16 units. When the additional data is available, the project’s ROI will be cal-culated and appropriate implementation decisions will be made.

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Marine Corps Equipment: Automated Vehicle Wash-Down System To preclude the early degradation of Marine Corps vehicles due to corrosion, a periodic wash down is necessary to remove surface contaminants that contribute to corrosion and affect vehicle readiness. In addition, when vehicles return from field exercises or deployments—and after cleaning—a final wash down prior to parking is necessary to remove this same material (such as road dust and salt-laden particles), particularly in seaside environments.

With the considerable time and effort involved to wash down every vehicle over a regular period, it is conceivable that full wash-down does not always occur on all assets. The manpower and time it takes to process all these vehicles likely prevents an adequate coverage, which limits the command’s assurance that corrosion is being inhibited. The goal of the project was to demon-strate an increased vehicle throughput, as well as cost savings associated with a drastic reduction in required manpower when using an automated vehicle wash-down system rather than washing vehicles by hand.

The project was designed and stood up using a site contributed by the 3rd Marines 3rd Regiment, Marine Corps Base Hawaii (MCBH) that was used previously for manual wash down of vehicles using a low water pres-sure delivery. Phase I of the task consisted of surveying the site to determine the effort required to refurbish the needed facility equipment and determine what was needed in the way of new equipment installation to bring the concept to operational status and whether any of the existing equipment could be used, repaired, or upgraded to support this effort. Phase II was to accom-plish the tasks necessary to bring the site to operational status with a new wash-down facility.

Figure VI-14. MCBH Automated Vehicle Wash-Down System

The existing facility was determined to be in excellent condition, and only minor re-pairs were required. The oil-water separator equipment was to be upgraded by another, separate project planned by the MCBH Base Facilities group. This was subsequently completed prior to equipment installation at the site—Phase II of the project.

During Phase I, the pumps that existed at the facility were found to be beyond repair and unusable, resulting in the purchase and installation of new pumping systems. A stationary double arch drive-through and one high pressure wand (located separately for a special function) were required. New piping and hose bibs were also needed to hold up to the harsh salt-spray environment.

Existing tanks and some piping were reused; however, other components required replacements, such as the water backflow preventer, a main water shutoff valve, and switching and controls. No

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digging was planned and the soil was not disturbed, which precluded environmental protection con-cerns. The existing site was found to have appropriate and ample electrical power and water supply. At the time of the project’s completion and start of the new wash-down capability operation, the new facility complies with existing environmental regulations.

Phase II began in March 2006, and installation and equipment checkout was completed on schedule in June 2006. Operational testing, procedures development, and data collection were ongoing for a short time thereafter. Because several months’ readings will be required for data collection of water usage, flow rates, electrical use, and vehicle throughput, the ROI calculation is preliminary; however, based on previous experience from the engineering firm that installed the equipment, and because the facility is used more frequently with the new capability, a posi-tive return-on-investment projection can be made at this time. This information can be used in the future in conjunction with the corrosion rate of each asset type that passes through the auto-matic wash-down system.

Phases I and II were completed on schedule and within budget. The project immediately found favor with similar groups at MCBH at the ribbon cutting ceremony. From the onset, the system’s ease of use was very popular with both the command and individual users. This can only insure its continued use and favor as a beneficial example of the tools of the Marine Corps’ Corrosion Prevention and Control program.

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Appendixes Appendix A: DoD Corrosion Executive Policy Memorandum

Appendix B: Summaries—FY2005 Funded Projects

Appendix C: Summaries—FY2006 Funded Projects

Appendix D: Summaries—FY2007 Funded Projects

Appendix E: Abbreviations

Appendix A DoD Corrosion Executive Policy Memorandum

A-1

COORDINATION VERSION 1 COORDINATION VERSION 1

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Appendix B Summaries—FY2005 Funded Projects

The following sections provide additional information on each of the approved weapon sys-tems and equipment and facilities and infrastructure FY2005 projects.

Weapon Systems and Equipment

AF-W-101: Corrosion Prevention Compound Implementation on C-5 Aircraft Purpose Application of corrosion preventive compounds (CPCs) to C-5 airframes is expected to significantly

increase corrosion protection in key areas. The project adapted existing corrosion prevention and control measures, identified C-5 structural areas that could benefit from CPCs, and applied CPCs with changes to maintenance and inspection requirements.

Technology Existing approved materials using recent technology evaluations for optimization of such materials and their applications.

Application All C-5 aircraft types. Benefits Avoids structural maintenance down time (thus increasing readiness). Enhances structural integrity and

safety. Near-term benefits expected to occur on identified corrosion problem areas on C-5 aircraft.

AF-W-107: Aircraft Electrical Connector Inhibitor Implementation Purpose Implementation of electrical connector lubricant and CPCs at field level for F-16 aircraft. Technology Existing materials and applications were previously approved but not mandated. Numerous

studies have proven significant returns on investment. Application All aircraft avionics and electronics. Benefits Cannot duplicate (CND) discrepancies and retest OKs (ReTOK) for avionics are reduced many

fold, improving mean time between failures (MTBF) rates and readiness. Initially being applied on F-16 aircraft.

AF-W-117: Rapid Cure Aircraft Coatings for Roller/Brush/Aerosols Purpose Develop rapid curing primers and topcoats that can be applied in austere locations to allow rapid

repair. Technology Primer samples were provided to the Air Force Research Laboratory (AFRL) for testing. The base-

line performance testing of the aerosol primer and topcoat have begun and a field demonstration for F-16 and A-10 aircraft is planned.

Application All Air Force aircraft. Benefits Enhanced readiness as aircraft are returned to operational status in a shorter amount of time.

N-W-201: Using Rapid-Cure Coatings for Well Deck Preservation Purpose Reduce the time needed to preserve amphibious ship well decks by using rapid-cure coatings. Technology Leverage product development under the Office of Naval Research (ONR)–sponsored single coat

program (Future Naval Capabilities–Total Ownership Cost). Application Rapid-cure solvent-free epoxies and polyurethanes, and their associated application technologies,

were assessed and demonstrated. Benefits Reduces the time for painting from the current 15-day process to a 2-day process. Surface prepa-

ration and setup are unchanged. OSD and Service funding yielded full-scale product screening and three trial installations.

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N-W-203: Wireless Corrosion Sensor for Surface Ships Purpose Reduce the cost and time spent performing preservation assessment inspections of shipboard

tanks and voids. Technology Wireless corrosion sensors will leverage the previous tank monitoring system (instrumented anode

with silver–silver chloride [Ag-AgCl] reference cells), including the wireless data logger. Application The electrochemical tank monitoring system provides continuous condition monitoring. Insertion of

wireless capability entirely eliminates need for tank opening for inspections. Benefits Eliminates opening, gas-freeing, and inspection costs of approximately $15,000 per tank, with

approximately 4,000 tanks inspected each year. Current inspection methods are time-driven and do not facilitate pre-availability planning.

N-W-208: Composite Electrical Boxes Purpose Replace brass electrical boxes that corrode and drive maintenance with corrosion-proof composite. Technology Leverage composite box technology from Air Force cargo aircraft to deliver cost-effective, corro-

sion-proof, fire-retardant, shock-qualified, and electromagnetic interference/electromagnetic pulse–(EMI/EMP-) hardened electrical boxes that directly replace current metallic boxes.

Application Replacing metallic boxes with composite boxes has been successful in the fleet via small-scale demonstrations on U.S.S. Rushmore (LSD 47) and U.S.S. Vella Gulf (CG 72). Development work in approximately 10 sizes per configurations should address shipboard connectors, lights, hand-sets, and junctions. The goal is to implement a family of composite boxes via large-scale demon-strations on Navy, Military Sealift Command, and Army craft.

Benefits There are approximately 75,000 electrical boxes aboard Navy ships. The use of composite boxes avoids costly re-preservation and replacement of metallic boxes. Three ship sets of electrical boxes were installed for demonstration and validation.

N-W-211: USMC Automated Vehicle Wash-Down System Purpose Provide a fixed, automated system that will perform efficient and effective cleaning (which is vital

for corrosion prevention and control) and be capable of washing 3,600 assets per year at substan-tial cost and manpower savings.

Technology Leverage an ongoing Office of Naval Research (ONR) program that is developing a transportable vehicle washdown system using existing technology developed for industrial truck washes.

Application Throughout the operating forces, where a lack of automated wash-rack facilities requires significant man-hours to be spent conducting maintenance wash-downs.

Benefits Will provide a fast and efficient method to perform maintenance wash-downs and enhance the corrosion control of assets. Also ensures compliance with environmental laws through wash water treatment. OSD funds were successfully applied for developing an automated vehicle washdown system for placement at Kaneohe Marine Corp Air Station (MCAS), Hawaii, (III Marine Expeditionary Force, MEF) where assets are subjected to extreme corrosion conditions.

N-W-212: On-the-Lot Dehumidified Storage Plan Purpose Develop an administrative storage program (ASP) that will extend the life of Marine Corps tactical

ground and ground support equipment and will reduce maintenance requirements and associated costs.

Technology Portable shelter systems that provide dehumidified storage of assets to protect them from the harmful effects of corrosion and exposure to wind, rain, moisture, and ultraviolet oxidation.

Application Throughout the operating forces, wherever lack of fixed storage facilities requires equipment main-tenance officers to find other means of storing equipment.

Benefits Increase in operational availability of Marine Corps assets and decrease in associated maintenance costs from placing equipment in administrative storage. OSD funds assisted III MEF’s efforts to purchase 48 storage systems for use at Kaneohe MCAS to collect data and establish an ASP.

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N-W-214: Improved Protective Coatings for Magnesium Components Purpose Reduce corrosion on magnesium alloy components and analyze systems for greatest perform-

ance. Corrosion of magnesium components, especially helicopter gearboxes, has always been a problem for aviation platforms. The poor corrosion resistance of magnesium, when coupled with corrosive environments, has led to premature component degradation and replacement. The com-ponent cost of replacing these gearboxes for the Navy and Marines H-60 is $291,000 for the main gearbox and $93,000 for the tail gearbox—not including labor.

Technology For touch-up repair and recoating. Coatings include conversion coatings, anodize, primers, top-coats, sealants, and CPCs.

Application Optimized magnesium corrosion protection system. Implementation at Naval Air Systems Com-mand (NAVAIR), Aviation and Missile Command (AMCOM), U.S. Coast Guard, and other users.

Benefits Protective coatings will reduce corrosion, which will reduce replacement costs, maintenance hours, and damage due to removal of current materials, and increase maintenance intervals. Program will provide increased reliability and maintainability and increased readiness of platform.

N-W-215: Av-DEC Sealants for Conductive Gaskets and Floorboard1 Purpose Reduce or eliminate corrosion at antenna and floorboard interfaces. Corrosion degradation of an-

tennas, for example, on the Navy’s EA-6B Prowler has historically led to the replacement of nu-merous antennas every year, costing $318,000 in FY2004 alone.

Technology Aviation devices (Av-DEC) gaskets and conductive for antenna applications and non-conductive for floorboards.

Application Applications include • full implementation of conductive gaskets on all Navy H-60s and EA-6Bs, • partial (25 percent) implementation of conductive gaskets on Army CH-47 Chinooks and

UH-60 Blackhawks being repaired at Corpus Christi Army Depot or RESET facilities, and • partial (50 percent) implementation of conductive gaskets on Air Force C-130 Hercules being

repaired in organic depots. Benefits Reduces or eliminates corrosion (reduced replacement costs, reduced maintenance hours, in-

creased maintenance intervals, and reduced damage due to removal of current sealants). Also reduces or eliminates communication “gripes” and failures during missions.

N-W-216: Improved Corrosion Prevention Materials and Processes Purpose Implement better products to prevent corrosion. Also fertilize processes across platforms, facilities,

and organizations. Technology Metalast is an improved process for aluminum anodizing. MIL-L-87177 improved CPC for avionics

and electrical components. Sacrificial repair coating solution where none exists. MIL-PRF-23377 N improved primers for support equipment.

Application This project provides a mechanism to insert corrosion technologies that have been demonstrated and validated through RDT&E support. It uses the information obtained from the fleet to prioritize and assess commercial technologies, performing an analysis of alternatives to down-select to the most promising candidates and conducting operational evaluations of these technologies.

Benefits Better anodize coatings for aluminum (2-times performance gains possible and more efficient proc-essing at depots). Better CPCs for avionics and electrical applications (longer lived, better electrical performance, and reduced maintenance hours and schedule). Fleet touch-up repair for cadmium where none exists. Two-fold performance improvement in SE corrosion resistance possible.

1 Av-DEC® (Aviation Devices and Electrical Components, LLC) is a technical design and manufacturing com-

pany that produces non-hazardous polyurethane based products for commercial and military aircraft. Specific areas of focus for corrosion prevention include aircraft-to-antenna mating surfaces, aircraft structural areas, and wire har-nesses and interconnects (See http://www.avdec.com/company.htm, accessed December 15, 2004).

AR-W-303: Clear Water Rinse System Purpose Clear water rinse for helicopters. Technology Installation of a clear water rinse system to reduce corrosion and corrosion events. Application Mitigate corrosion processes and damage to helicopters. Benefits Improves aircrew safety, reduces maintenance and support costs, and improves readiness. Also,

the water used for rinsing is filtered and recycled.

AR-W-305: AMCOM–NAVAIR Corrosion Partnership Purpose Capture synergism of Army and Navy corrosion reduction efforts for helicopters. Technology The AMCOM-NAVAIR Corrosion Partnership includes direct support to the Aviation RESET PMO,

performing Army Aviation lead duties for the Joint Council on Aging Aircraft Corrosion Steering Group (JCAA-CSG), and preparation and submission of program requirements for Army aviation and missiles corrosion prevention programs to the Army Materiel Command and the Office of the Secretary Defense. Specific tasks associated with this project included visits to RESET sites to perform corrosion assessments of aircraft, identification of corrosion technology solutions, and conducting corrosion technology training visits for RESET sites worldwide.

Application This single-phase project continued the joint partnership through the identification and implemen-tation of new corrosion technologies for Army and Navy aircraft. Deliverables included newly iden-tified corrosion technologies that have a long-term effect for insertion into Army and NAVAIR aviation programs including a new Melamine Cleaning Pad and Mildew Remover kit; technical manual and naval aviation training and operating procedures standardization (NATOPS) changes to reflect new corrosion processes or procedures; returning and outbound Southwest Asia helicop-ter corrosion assessments and analyses; monthly status reports; onsite corrosion training for Army users; and analyses of the costs of corrosion identified during partnership corrosion assessments. The result has been a reduction in the duplication of efforts and more efficient use of Army and Navy resources.

Benefits Improves aircrew safety, reduces maintenance and support costs, and improves readiness.

AR-W-309: Army Corrosion Control Kit Purpose To eliminate the need for the Tyvek suits, full-face respirators, and other personal protection

equipment. Technology User friendly dust-less tools and HEPA (High Efficiency Particulate Air) filtered portable vacuums

are used to help collect the dust as it is being generated and minimize clean-up time and waste. Application These tool kits can be used on any vehicle or machine that needs surface corrosion removal. Benefits This kit is used to enhance surface preparations in order to improve coating adhesion to the sub-

strate as well as help remove rust and thereby eliminate the need for costly depot restoration.

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Facilities/Infrastructure Projects

AF-F-116: SCADA Monitoring of Cathodic Protection Systems, Robins Air Force Base Purpose To remotely monitor—through supervisory control and data acquisition (SCADA)—cathodic protec-

tion system operation, to ensure they meet Air Force Regulations, NACE standards, and the Code of Federal Regulations.

Technology Uses hardwire and radio unit instrumentation to transmit real time voltage and current readings back to central monitoring.

Application Fuel and water tanks and piping, natural gas lines. Impressed current rectifiers and test stations. Benefits Provides constant, real time monitoring of corrosion protection systems to meet environmental

standards, thus avoiding potential leaks, spills and the resultant fines and cleanup. Enhances maintenance and optimal operation. Project served as a test program to provide techniques of successful design and installation of remote monitoring systems to other military installations.

N-F-221: Self-Priming Cladding for Splash Zone Steel Purpose Increase service life of the coating of splash zone steel. The “splash zone” is defined as the area

between the year’s lowest tidal mark and up to ten feet above the year’s highest tidal mark. It is extremely difficult to protect steel structures against corrosion in this zone where corrosion rates have been documented to exceed 30 mils per year on unprotected steel.

Technology New Small Business Innovation Research (SBIR) developed technology employs 40+ mils epoxy novolac/polysulfide.

Application Full scale field installation at San Diego, California and Pensacola, Florida. It was a tri-Service effort that included accelerated laboratory weathering. Will support either a new DoD standard or an amendment to an existing one.

Benefits Fifty percent increase in service life, shop-applied or field maintenance, and projected savings of $18.7M per year (816,000 sq. ft.).

N-F-222: Red Hill Pipeline Corrosion Assessment, Fleet Industrial Supply Center (FISC) Pearl Harbor Purpose Conduct an in-line inspection of a 32-inch diesel pipeline from the Red Hill Storage Facility to

Pearl Harbor to determine the extent of corrosion and integrity of the 62-year-old pipeline. Technology Evaluation of magnetic flux and ultrasonic “smart pigs” (inspection vehicles that move inside a pipe

pushed along by the flowing material) for determining fuel pipeline condition. Application Thirty-two-inch diesel pipeline from the Red Hill Storage Facility to Pearl Harbor, Hawaii. Benefits Determined the extent of corrosion and integrity of the 62-year-old pipeline to eliminate risk of un-

expected failure and resulting environmental costs; allows long-term capital investments planning and scheduling of repairs with minimum impact to mission; increases operability of the pipeline; and increases precision in long-term planning of fuel logistics in the Pacific theater. Also served as test program to provide techniques of successful pipeline integrity evaluation using “smart pig” technology for other DoD distribution pipeline facilities.

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N-F-223: Ambient Temperature Cured Coatings Purpose Define the functional parameters for application and use to: improve long-term performance; reduce

maintenance costs; compile and assess ongoing installation at Jacksonville Naval Air Station (NAS). Technology Non-traditional, commercially available coatings technology; silicon based coating technology;

other non-organic coating systems; and other advanced/non-traditional coating systems. Application Primary interest: steel structures in aggressive environments. Secondary interest: other substrates

and environments to maintain or restore existing coating systems. Benefits Reduces facility maintenance costs, allows restoration without complete recoat, and improves

tri-Service specifications.

N-F-229: Integrated Concrete Pier Piling Repair and Corrosion Protection System Purpose Install a commercially available, integrated concrete pier piling repair and corrosion protection sys-

tem on spalled or cracked concrete pier piling. Technology Integrated concrete repair and cathodic protection (CP) prefabricated in a fiberglass jacket (“life-

jacket”). It is commercially available, with an estimated 20-year service life, and easily installed by a contractor.

Application Field installation/demonstration at Pearl Harbor. Installation on 80 of the more than 350 piles being repaired as part of $10 million Commander Naval Region Hawaii (CNRH) pier repair project.

Benefits Restores structures to optimum operational condition; reduces recurrence of reinforcing steel cor-rosion; reduces maintenance and life-cycle costs; and increases service life. The project served as test program for the “lifejacket” technology.

AR-F-311: Measuring the Rate and Impact of Corrosion Damage on DoD Equipment and Installations Purpose To develop site-specific corrosion data and model local corrosion impact on various materials. Technology Integrate corrosion rate measurement at various sites based upon the innovative Battelle corrosion

exposure rack system. Also develop criteria for more effective management of corrosion based on the determined corrosion rates.

Application Corrosion test sites at over 75 DoD, NASA, and Coast Guard locations. Benefits Optimization of materials selection and corrosion management approaches based upon local envi-

ronmental conditions. Ensures mission readiness, including critical equipment and facilities. Pro-ject provided site-specific corrosion rate data and supports the development of guidance and standards based upon local corrosion rates for equipment deployment and facility construction.

AR-F-313: Leak Detection for Pipes at Fort Hood Purpose To implement leak detection technology on the potable water distribution system. Technology Remotely monitored acoustic sensors detect and record characteristic leak signatures in water

distribution piping. DoD-developed signal processing will discriminate leak signals from back-ground noise and determine approximate location of leak. Leak information will be used to target and repair areas of worst corrosion first.

Application Residential section at Fort Hood, Texas. Benefits Maintains operational and training readiness by supporting deluge requirements, greatly reduces

money spent on lost water, and reduces manpower needed to locate leaks. Project provided site-specific capability to detect leaks in the water distribution system; also developed the design guid-ance and specifications for implementation of leak detection and location technology for water distribution systems throughout DoD. Project provided capability to extend the acoustic leak detec-tion technology to other utility distribution systems such as fuel.

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AR-F-314: Non-Hazardous Corrosion Inhibitors/SMART Control Systems for Heating and Cooling Purpose To implement an improved approach for controlling corrosion, scale, and microbiological growth in

boilers and cooling towers. Technology Innovative non-hazardous green chemical treatments and a smart monitoring and control system. Application The smart monitoring and control system self-adjusts corrosion inhibitor application based on real

time corrosion rates. Control systems were installed at seven cooling towers at Ft. Rucker, eleven cooling towers at Ft. Hood, three cooling towers at Redstone Arsenal, one cooling tower and one boiler system at Brooke Army Medical Center, and two towers and one boiler system at Red River Army Depot. The systems received 15 months of green chemical treatments. Five sites allowed the treatment to be tested with a variety of equipment, demand and feed-water parameters. Addi-tional Army Installations received boiler safety inspections.

Benefits Maintains system at optimum treatment levels, reduces failure and downtime, improves safety, minimizes worker contact with treatment chemicals, and ensures heating and cooling for mission-critical equipment and training. Project served as a test program for non-hazardous chemical treatments and control systems; also developed design guidance and specifications for implemen-tation of green chemical treatment and smart monitoring and controls for heating and cooling sys-tems throughout DoD.

AR-F-317: Pipe Corrosion Sensors at Fort Bragg Purpose To implement in-situ sensors that continuously monitor the potable water corrosivity and piping

corrosion. Technology Integrated new generation sensors measure several water quality parameters and assess corro-

sivity so that water treatment can be tailored to current conditions. In addition, linear polarization resistance sensors will measure actual pipe corrosion rates; problems can be pinpointed and the effectiveness of corrosion control can be monitored and quantified.

Application Sensors were installed at critical locations in the water distribution system at Fort Bragg (e.g., air-craft deluge systems and fire protection piping for medical facilities). These sensors can be applied DoD-wide at any installation with a potable water system. They can also be used by the govern-ment to provide monitoring and oversight of privatized and contractor-operated water systems.

Benefits Improves water quality, improves safety and reliability of fire suppression systems, and reduces lifecycle costs of water distribution systems. These sensors have a dual benefit in that they can also be used to improve potable water system security by detecting changes in water chemistry. Project served as test program for in-situ water corrosivity and pipe corrosion sensors; also devel-oped design guidance and specifications for implementation of pipe corrosion sensors in water distribution systems throughout DoD.

AR-F-318: Ice-Free Cathodic Protection Systems for Water Storage Tanks at Fort Drum Purpose To implement ice-free cathodic protection (CP) systems to mitigate corrosion inside potable water

storage tanks in cold climates. Technology Innovative CP system is comprised of ceramic-coated wire anodes and a flotation and support

system. Ice will no longer destroy CP systems, and the interior of the tank will be continuously protected from corrosion damage.

Application The technology was installed in two elevated water storage tanks at Fort Drum during this project. It is applicable to all DoD elevated water storage tank facilities where ice formation can occur in the winter. It is also a superior CP design for all elevated and on grade steel water storage tanks.

Benefits Enhanced safety and reliability for potable water systems; avoidance of unplanned storage tank failures (and resulting loss of fire suppression capability); improved water quality; reduced mainte-nance costs; and ensures mission readiness, deployment, and training requirements are met. The frequency of expensive interior tank recoating will be reduced. Project also served as test program for ice-free CP systems; also developed design guidance and specifications for implementation of ice-free cathodic protection systems for water storage tanks throughout DoD.

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AR-F-319: Corrosion Resistant Materials for Water and Wastewater Treatment Plants at Fort Bragg Purpose Implement advanced materials selection for water and wastewater treatment plants. Fort Bragg

has identified severe corrosion problems at both the water treatment plant (WTP) and the waste-water treatment plant (WWTP) due to the harsh environments of sewer gases and chlorine.

Technology Judicious selection of emerging corrosion resistant coatings and alternative materials can provide improved corrosion protection. Included are new concrete restoration coatings, UV resistant coat-ings and gaskets, polyurethane coatings for lampposts, fiberglass composite doors and corrosion resistant alloy components.

Application Various components at Ft. Bragg WTP and WWTP, including concrete filter tanks, metal piping, metal troughs, electrical boxes, and chlorination building.

Benefits Restoration of WWTP to optimum operation condition. Water is critical for operations and deploy-ment. In addition, the WWTP must meet environmental regulations. Design guidance and specifi-cations were developed as part of this project for implementation of corrosion-resistant materials for WTPs and WWTPs throughout DoD.

AR-F-320: Surface Tolerant Coatings for Aircraft Hangars, Flight Control Tower, and Deluge Tanks at Fort Campbell Purpose To implement surface tolerant coating technology on steel structures. Technology Overcoat existing deteriorated coatings with minimal surface preparation including moisture cure

polyurethane coatings and new fluoropolymer coatings. Applies new self-healing coatings on criti-cal surfaces.

Application One flight tower, two hangars, and two deluge tanks at Fort Campbell. Benefits Restores structures to optimum operation condition, reduces maintenance, and increases safety.

Project served as test program for surface tolerant coatings/self healing coating technology; also developed design guidance and specifications for implementation of surface tolerant coatings on steel structures throughout DoD.

AR-F-321: Remote Monitoring and Cathodic Protection Upgrades at Fort Carson Purpose Fort Carson is spread over a large area and has many water storage tanks that use special corro-

sion protection system known as cathodic protection systems, which protect the internal or “water-side” of the tank. The outer surfaces of underground pipes (such as water, gas, or fuel distribution systems) must also be protected from corrosion in the soil using similar CP systems. In either case, CP systems need to be monitored in order to make sure that they are providing enough volt-age and current to maintain the cathodic protection.

Technology Upgrade existing CP systems using new ceramic anodes, and new drive-by remote monitoring of variables such as corrosion potentials and current for CP system rectifiers and test stations.

Application This technology was implemented on five water reservoirs and pipelines: 30 miles of water distri-bution, 40 miles of natural gas, 2 miles of fire suppression, and 5 miles of steam line.

Benefits Provides capability to remotely monitor performance of CP systems to protect critical DoD utility systems, such as fuel and water distribution systems. CP systems will thusly be better maintained; alerts personnel of problems; increases reliability and safety. Design guidance and specifications were developed as part of this project for implementation of CP remote monitoring systems throughout DoD.

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AR-F-322: Cathodic Protection of Hot Water Storage Tanks Using Ceramic Anodes at Fort Sill Purpose Implement technology to mitigate hot water storage tanks corrosion. Technology Impressed current cathodic protection (ICCP) systems using new ceramic anodes. New hot water

storage tanks with corrosion-resistant linings and sacrificial anodes. Application This project implemented ICCP for six 1,000–3,000 gallon hot water storage tanks and linings and

sacrificial anodes for 17 smaller (37–1,000 gallon) hot water tanks and heaters at Fort Sill. Benefits Extends serviceable life of large-capacity hot water storage tanks and prevents potential water

damage to electrical and mechanical systems due to leaking tanks. Design guidance and specifi-cations were developed as part of this project for implementation of ceramic anode CP systems for hot water storage tanks throughout DoD.

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Appendix C Summaries—FY2006 Funded Projects

The following sections provide additional information on each of the approved weapon sys-tems and equipment and facilities and infrastructure FY2006 projects.

Weapon Systems and Equipment

WAR07: PEO ASMD Patriot Missile Cable Connector Protective Covers Purpose Demonstrate and Validate (DEM/VAL) a protective covering for the Patriot Missile System that,

when applied to cable connectors, will eliminate replacements due to corrosion damage. Technology Cable covering material to prevent and control corrosion of electronic cable connectors. Test re-

sults from the Army’s Redstone Arsenal Materials Laboratory and the U.S. Naval Air Systems Command (NAVAIR) in the Army Aviation and Missile Command (AMCOM)/NAVAIR Corrosion Partnership demonstrate the ability of the cable covering material to function under actual field conditions in all theater environments.

Application Critical cable connectors for Patriot Missile System components in highly corrosive environments. Phase one of the project entails: procurement and installation of cable connector covers on 145 Patriot Missile Systems; connector cover installation training; and field data gathering, analysis and results publication.

Benefits Protective covers will abate the overall effects of corrosion and increase weapon system availabil-ity rates/readiness.

WAR12: Demonstration and Validation of Quasi-Crystalline Coatings Purpose To produce several sets of quasi-crystalline coated field cookware for in-house and field testing;

optimize the coating process and develop a pilot electroplating production line with process docu-mentation; validate performance and cost savings; and facilitate transition of commercially avail-able cookware to procurement.

Technology Aluminum-rich quasi-crystals are electroplated with nickel on a surface using standard electroplat-ing equipment. The resulting quasi-crystalline coating is durable and scratch and corrosion resis-tant. Independent testing shows that the coating is almost twice as hard as a typical stainless steel and as nonstick as Teflon.

Application All field cookware, pots, pans and sheets. Benefits Quasi-crystalline coated cookware is expected to result in: 25 percent less field sanitation labor;

50 percent less fuel, water and water disposal; decreased life-cycle cost due to 10-year useful life; and increased food safety.

WNA01: Enhanced Self-Priming Topcoat Purpose Multi-platform, multi-location fleet demonstration and validation of the field performance of a newly

developed Enhanced Self-Priming Topcoat (eSPT). Technology Polyurethane self-priming topcoat with advanced non-chromate corrosion inhibitors and extended

weathering properties. Application Various Navy and Marine Corps aviation weapon systems. Benefits eSPT is expected to achieve corrosion performance similar to current chromate primers but with

improved adhesion and weathering characteristics compared to the current non-chromate SPTs. Eliminating traditional spray primer requirements for all aircraft and increasing the performance of the topcoat will reduce work cycles and maintenance for painting operations. Using eSPTs will yield an estimated yearly savings of about $2,000 per aircraft in addition to increased weapon sys-tem readiness.

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WNA03: Mil-Spec Primers and Topcoats in New 1 & 2 Component Aerosol Delivery Cans Purpose Implement new primers and topcoats that are authorized per military specification and are as easy

to use as the existing aerosols currently in the system. Technology One- and two- component aerosol primers and topcoats. Application Navy, Marine Corps, Army and Air Force aviation platforms, including weapon systems and sup-

port equipment. Benefits Using proper primers and topcoats during touch up coating repair will provide better repair capability,

extended repair corrosion resistance and reduce labor, paint, and hazardous waste disposal costs. The reduction in man-hours alone is expected to yield a cost benefit of approximately $3M annually.

WNA05: Aircraft Shelters Purpose Purchase and install aircraft shelters at high-corrosivity land bases. The impact of the shelters will

be validated by tracking corrosion prevention and control maintenance on fleet EA-6B and F/A-18 aircraft and evaluating environmental severity under sheltered conditions.

Technology Lighted, turn-key, environmental shelters to house one aircraft during normal parked operations. Application Three shelters for fixed wing aircraft at Naval Air Station (NAS) Whidbey Island and NAS Oceana. Benefits Although the real, accrued benefits of aircraft shelters will be validated by this project, potential

maintenance labor savings are estimated to be about 20 percent. Additionally, annual reduction of use and disposal of corrosion prevention and control materials is estimated at $5K per aircraft. Other benefits include overall reduction of airframe degradation, maintenance scheduling flexibility and increased aircraft availability.

WNA19: Corrosion Preventive Compounds (CPCs) Purpose Validate performance of a long-lasting CPC on multiple platforms in the Army, Navy, and the Ma-

rine Corps. Technology Navguard—a new, high performance, long-lasting CPC for internal airframe and vehicle applica-

tions. Laboratory testing of this CPC showed superior corrosion resistance. Application Aviation weapon systems, support equipment and avionics. Targeted platforms include rotary and

fixed-wing aircraft such as the H-46, EA-6B, and F/A-18 located at Naval Aviation Depots (NADEPs) and air stations where test assets are based.

Benefits Increased CPC performance will reduce material costs and maintenance intervals for CPC re-application and will ultimately lead to improved fleet readiness. Reduced corrosion repair costs, including reduced maintenance man-hours, as well as decreased down time due to fewer inspec-tions and maintenance actions will generate a significant cost savings. Estimated average annual savings per aircraft is approximately $1,000.

WNS11: Corrosion Detection Algorithm for Ship’s Topside Coatings Purpose Modify existing Corrosion Detection Algorithm (CDA) to allow it to be used for Top Side Shipboard

Coating Condition Assessments. Technology The current CDA uses video imagery to perform coating inspections in tanks and void spaces in

order to quantitatively determine corrosion damage. The modified CDA will be able to analyze im-ages taken with a variety of hand-held digital cameras allowing for routine inspection, imaging and analysis of topside spaces. A database of these images would be a source and archive for analy-ses performed by a Topside-CDA (TCDA).

Application Aircraft carriers, surface combatants and amphibious ships. Benefits A quantitative and objective tool to evaluate topside corrosion and coating damage will eliminate

the need for costly and error-prone human inspection. Additionally, the use of condition-based maintenance will avoid structural damage, improve readiness, and enhance personnel safety.

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WNS18: Self-Inspecting Coatings Purpose Development and application of cost-effective, self inspecting coating techniques to ensure proper

application coating thickness without the need for cumbersome statistical measurement processes. Technology Self-inspecting coatings change color consistency and contrast proportionally to the required Dry

Film Thickness (DFT) for each coat applied while assisting the applicator in developing a consis-tent accumulative overall total DFT for the coating system.

Application Navy ships, tanks and voids. Benefits Transitioning from legacy coating systems to self-inspecting coating technology will reduce the

time between coats by eliminating current wet film thickness measurements and minimizing DFT measurements in determining coating thickness during application. Estimated annual reduc-tion of tank maintenance preservation is $16M.

WAF01: Magnesium Rich Primer for Chrome-Free Aircraft Coating Systems Purpose Develop a chrome-free coating system based upon a magnesium-rich primer. Refine primer proto-

type formulations, perform laboratory testing, and evaluate field-level performance. Technology Magnesium-rich primers cathodically protect aluminum substrates until the magnesium particles

present in the coating film are consumed. This innovative approach for effective and fully chrome-free corrosion protection is modeled after the well-established sacrificial zinc-rich primers that have been used to protect steel structures for decades.

Application Applies to all DoD aluminum alloy assets which currently utilize toxic, chromate-based surface treatments and primer coatings for corrosion protection.

Benefits The use of an effective, magnesium-rich, chrome-free coating system will eliminate significant costs resulting from the current use of chromium compounds for corrosion protection of aluminum alloys. Reductions in chrome waste disposal, workers compensation, and OSHA compliance are expected to yield approximately $2M annual savings.

WAF02: Prevention of Sand Induced Circuit Card/Electrical Interconnect System Corrosion Purpose Define the probability and quantify the severity of corrosion due to dust and sand contamination.

Identify optimal, remedial cleaning practices that minimize corrosion consequences and restore components to the best condition possible. Document these cleaning strategies for insertion into applicable technical orders and/or field maintenance bulletins.

Technology Design of experiments approach to determine the impact of sand contamination, humidity, tem-perature, and protective mechanisms, on the electrical degradation of circuit board surfaces, wiring terminals and connector interfaces.

Application Program focuses on flight critical aircraft systems; technology applicable to all DoD electronics systems. Benefits Determining the magnitude and probability of system corrosion will remove the unpredictability of

maintenance and readiness burden and will eliminate unexpected line replaceable unit (LRU) fail-ures. Identifying and implementing effective cleaning strategies will minimize the extent of corro-sion damage, reduce field failures, and limit future maintenance burden.

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WAF03: Wash/Rinse Program Purpose Measure and evaluate the effects of extended wash and rinse intervals for operational aircraft in

benign and severe environments. Optimize the frequency of wash/rinse activities based on effi-cacy in reducing corrosion and cost/benefit analysis. Flight test optimized washing and rinsing procedures and incorporate them into Technical Order (TO) 1-1-691: Aircraft Weapons Systems—Cleaning and Corrosion Control.

Technology Measure and evaluate the effects of washing via flight testing of alternative extended wash cycles on operational aircraft in a more benign environment and measuring and evaluating alternate, in-creased rinsing on operational aircraft in a more severe environment.

Application Flight testing in benign environments on C-130 aircraft at the 179th Airlift Wing (AW) in Mansfield, Ohio. Flight testing in severe environments on H-60 aircraft assigned to the 920th Rescue Wing (RQW) at Patrick AFB, Florida. Project implementation will be applicable to all air vehicles and the results will be evaluated by the Army and Navy to determine applicability to their own wash and rinse programs.

Benefits Optimized wash/rinse program is expected to reduce corrosion in more severe environments while eliminating the need for these actions in more benign environments where there may be little cost benefit. Annual direct cost savings resulting from reduced frequency of wash/rinse activities is es-timated to be $7M. The availability of airframes is also expected to increase.

WAF04: Cumulative Environmental Exposure Sensors (CEES) for C-130 Fleet Management Purpose Install CEES in order to characterize the environmental conditions experienced by individual air-

craft at opposite ends of the fleet service life spectrum. Determine corrosion inspection frequen-cies, tailor wash cycles and the frequencies of corrosion preventative maintenance actions. Evaluate existing inspection and maintenance activities to enable condition-based maintenance resulting from the understanding of aircraft operating and environmental exposure.

Technology CEES are made using printed copper circuits. The sensors are small, light-weight, self-contained, and require no power source. Collected data can be easily downloaded during regular mainte-nance actions. This data characterizes the actual environmental spectrum, allowing the weapon system manager to assess the actual degradation of the aircraft structure in order to support sus-tainment decisions. Cumulatively, the data will also assist in assessing the overall health of the fleet and estimating the impact of corrosion on overall structural integrity.

Application Approximately 40 Air National Guard (ANG) C-130 and C-130J aircraft with 20 sensors each. Benefits Increased knowledge of the airframe environment and progression of corrosion will permit major

reductions in unnecessary maintenance and unplanned repairs resulting from unexpected corro-sion and will enhance the ability to effectively and comprehensively manage corrosion. The im-proved ability to monitor the corrosion condition of the airframe will also reduce maintenance burdens, thus increasing aircraft availability and fleet readiness. Estimated annual direct cost avoidance is $180K per aircraft.

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WAF07: Rapid Cure Aircraft Coating System Formulated for Roller/Brush Application Purpose Produce a rapid cure roller/brush- or aerosol-applied aircraft coating system that can be used in

austere locations and evaluate in both laboratory and field environments. This complete solution will allow the field maintainer to rapidly repair aircraft coating systems, maintaining excellent corro-sion protection for the aircraft, and rapid return of the aircraft to operational status.

Technology Reformulation involves the integration of rheology modifiers and cure catalysts into the current paints. End product will consist of an additive package that can be incorporated during mixing to the existing advanced performance coating (APC) quality topcoats and primer formulations.

Application Applies to all Air Force (and potentially other services) aircraft that require coating system repair in field and forward operating locations.

Benefits A rapid cure aircraft coating system will allow timely repair of aircraft paint systems, keeping the corrosion protection system for the aircraft intact without requiring prohibitively long repair times. It will also save manpower, increase aircraft availability and mission readiness. Estimated savings from the reduction of paint material and clean-up costs are $1.2M annually. In addition, estimated corrosion-related savings are nearly $7M annually.

WAF09: Develop and Qualify DIEGME Resistant Fuel Tank Coatings Purpose Develop a commercially available, field and laboratory tested, integral fuel tank coating that is both

compatible with and resistant to the corrosiveness of the di-ethylene glycol monomethyl ether (DIEGME) required in the fuel tank.

Technology A combination of evolutionary and new technological approaches will be harnessed to formulate a new coating using new polymer binder systems including polythiol ethers, polysulfides, and polythiolenes.

Application Applies to all DoD aircraft, specifically B-52 and KC-135, with integral fuel tanks that utilize DIEGME as the fuel system ice inhibitor.

Benefits The use of a DIEGME-compatible fuel tank coating is expected to reduce maintenance by 16,500 hours annually (~$2M) for the B-52 and 35,475 hours annually (~$1M) for the KC-135. Other benefits include decreased scheduled and unscheduled maintenance, increased aircraft availability, decreased operating/life-cycle costs, and decreased operational risks. Cost avoidance savings are expected to approach $22M annually.

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Facilities/Infrastructure Projects

FAR01: Electro-Osmotic Pulse Technology Purpose Employ electro-osmotic pulse (EOP) technology to combat water seepage through concrete walls

and floor in ammunition storage igloos in order to reduce corrosion of munitions and equipment and improve the air quality in the igloos.

Technology EOP technology, an alternative to conventional water control techniques, mitigates water-seepage problems from the interior of affected areas without excavation. Based on the concept of electro-osmosis, EOP technology uses a pulsating electric field to generate movement of electrically charged liquid particles.

Application Eleven ammunition storage igloos at Fort A.P. Hill, Virginia. This project has the potential for far-reaching impact across the Army, the Tri-services, and the Defense Ammunition Center as similar problems are present throughout DoD. It is the intent of the Project Management Plan (PMP) to implement this corrosion prevention and control technology at multiple Army regions and installa-tions in the future, as well as to other Tri-service sites.

Benefits Permanently dry ammunition storage igloo interiors will result in reduced corrosion of both stored equipment and facilities infrastructure. Eliminating water seepage will also enhance the air quality of these structures. Operational benefits of implementation include enhanced lifecycle costs, in-creased life-safety of soldiers, and greater reliability of ammunition and equipment. The useful life savings (ULS) resulting from this technology is projected to be $8.7M. Specifications and stan-dards will be developed for implementation of EOP in ammunition storage igloos at other DoD locations.

FAR02: Smart Fluorescent and Self-Healing Coatings Purpose Demonstration and validation of advanced smart-fluorescent and self-healing coating technologies

in operational environments. Proper selection and implementation of these advanced coatings in order to sustain restoration of major components of Central Vehicle Wash Facility (CVWF).

Technology Smart fluorescent, self-healing coatings, when built into the primer and topcoat, indicate where the coating has been damaged and self-repair the damaged areas. Commercially available paints to which new optically active materials are added will fluoresce under ultraviolet light inspections, revealing areas at risk due to incomplete coverage, holidays, and corrosion. Self-healing coatings contain film-formers and corrosion inhibitors that are released when the coating is damaged in order to repair the damaged areas and prevent further corrosion.

Application Smart fluorescent and self-healing coatings will be applied to the CVWF at Fort Bragg, North Caro-lina.

Benefits Implementation of smart fluorescent and self-healing coatings will restore the CVWF to its opti-mum operating condition and allow for early detection and correction of corrosion. This will result in reduced maintenance, enhanced safety and reliability, and 30 year life extension for mission-critical infrastructure. Implementation of this project is expected to realize ULS of $14.8M. Specifi-cations and standards will be developed for implementation of smart fluorescent and self-healing coatings at other DoD locations.

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FAR03: Green Water Treatment Purpose Design, install, and operate environmentally friendly, or “green”, inhibitor formulations and smart

monitoring and control systems in order to improve the reliability and reduce the cost of operating and maintaining heating and cooling towers.

Technology Green formulations are biodegradable and nontoxic, can be disposed of safely and inexpensively, and are produced with minimal negative environmental impact. The mixed oxidant (MIOX) process is a new disinfectant process that eliminates bio-fouling, reduces corrosion and scaling, and elimi-nates the need for chlorination in cooling water systems. Glycol alternatives replace ethylene and propylene glycols and offer both freeze and corrosion protection of heating systems.

Application Green water treatment and smart control will be implemented at Fort Wainwright (Alaska) and the U.S. Military Academy at West Point (New York) on a total of five heating and eight cooling sys-tems.

Benefits Installation of advanced, green inhibitor formulations combined with smart control system tech-nologies will enhance the performance, reliability and safety of heating and cooling systems. Main-taining optimum operating conditions will reduce maintenance and downtime thus lowering lifecycle costs. Implementation of this project is expected to realize ULS of $15M. Specifications and standards will be developed for implementation of green water treatment and smart monitoring and controls for heating and cooling systems at other DoD locations.

FAR04: Remote Corrosion Sensors for Detection of Corrosion on Mission Essential Structures Purpose Field demonstration and validation of remote corrosion sensors. Install sensors on mission critical

structures and monitor transmitted corrosion rate data. Technology Remote sensors, when applied to the surface of a mission critical steel structure, will report corro-

sion rates using linear polarization resistor technology. This technology allows the sensor to detect moisture intrusion, which indicates a change in the local corrosive environment.

Application Mission critical structures, such as C4ISR facilities and roof of motor pool building at Okinawa. Benefits Remote corrosion sensors can determine where corrosion is imminent, thus indicating which areas

need immediate attention and allowing for optimal maintenance scheduling. Early detection and prevention of corrosion will extend structure service life and lower lifecycle cost. Implementation of this project is expected to realize ULS of $12.6M. Specifications and standards will be developed for implementation of the remote corrosion rate monitoring technology at other DoD locations.

FAR11: Innovative Thermal Barrier Coatings Purpose Apply thermal barrier coatings to piping in heat distribution system (HDS) manholes in order to

prevent heat loss, improve safety for maintenance workers, protect steel piping, and create a less corrosive environment.

Technology Liquid ceramic coating to apply to newly constructed, bare, manhole piping. This coating technol-ogy has been used for over ten years in industrial settings. In addition, an indicator coating will allow maintenance workers to easily determine by visual inspection when recoating is necessary.

Application The coating will be applied in 10 or more manholes at Fort Jackson, South Carolina. Benefits Thermal barrier coatings will enhance thermal efficiency while protecting the piping from corrosion,

in part through environmental modification. This will extend the useful service life of the piping, increase reliability, and lower lifecycle costs. The coatings will also improve maintenance worker safety. The estimated ULS from this project is $6M. Specifications and standards will be devel-oped for implementation of thermal barrier coatings for HDS piping at other DoD locations.

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FAR13: Coating System for Corrosion Prevention and Fire Resistance for Metal Structures Purpose Apply coating system to metal structures in order to prevent corrosion and provide fire resistance. Moni-

tor the coating performance over a one-year period to validate the technology for use across the DoD. Technology New, innovative, epoxy intumescent coatings contain nano-corrosion inhibitors and can prevent

steel from weakening when exposed to high temperatures. The coating is virtually maintenance-free and can withstand extreme environmental conditions.

Application The coating system will be applied to one hangar and one additional structure at the Rock Island Arsenal (Illinois).

Benefits The coating will provide excellent protection against atmospheric corrosion, extending surface life by 15 years while reducing maintenance costs. In addition, the results of this project will be used to optimize materials selection and corrosion management approaches at other installations. The technology will enhance performance, reliability, and safety of DoD equipment and facilities. The projected useful life savings for this project is $9M.

FAR15: Development of Corrosion Indices and Life Cycle Prediction Purpose Provide a basis for planning corrosion prevention and control by establishing rates of corrosion

and impact of corrosion damage in specific environments. Technology A downloadable software package will use previously collected data on the corrosion effects of

various environments on equipment and facilities to assign a corrosion index to a given site based on environmental data. The corrosion index will allow the user to select appropriate corrosion re-sistant materials, coatings, cathodic protection, and water treatment for use in project specifica-tions and maintenance practices.

Application Applicable to all DoD installations. Benefits Using corrosion indices to predict environmental effects and lifecycles will allow for more effective

corrosion management of DoD equipment and facilities. This will lead to enhanced performance, reliability, safety, and improved design guidance and specifications for corrosion prevention and control.

FAR16: Corrosion Prevention of Rebar in Critical Facilities Purpose Application of concrete rehabilitation migrating corrosion inhibitor and cathodic protection com-

pound to prevent corrosion of rebar and deterioration of concrete in critical facilities. Technology A migrating corrosion inhibitor and a zinc-rich sacrificial coating that can be sprayed, brushed or

rolled onto a concrete surface to protect rebar and mitigate deterioration of concrete. An electro-chemical reaction between this compound and steel rebar causes the coating to oxidize slowly over many years while providing corrosion protection to the concrete surface below.

Application Fuel patrol bridge and a girder ring of a warehouse in Okinawa. Benefits Migrating corrosion inhibitor coating will reduce the permeability of the concrete to water and the

corrosion inhibitor will reduce the corrosion of the steel rebar. Zinc-based sacrificial coating will provide cathodic protection to the rebar, thus extending the life of the bridge and increased safety. Additional benefits include reduced maintenance and increased operational readiness and reliabil-ity. Implementation of this project is expected to realize ULS of $12.6M. Specifications and stan-dards will be developed for implementation of these technologies to prevent corrosion of rebar at other DoD locations.

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FAR20: Ceramic Anode Upgrades Purpose Upgrade ceramic anodes in a potable water storage tank and install cathodic protection systems

on underground natural pipelines. Also install cathodic protection test stations with remote monitor-ing systems that alert base maintenance personnel of potential problems.

Technology Cathodic protection systems, consisting of deep well ceramic tubular anodes, to protect surfaces, such as the exterior of steel pipes buried in the soil and the interior of potable water storage tanks, from corrosion damage.

Application A two million gallon potable water storage tank and underground natural gas distribution piping in the severely corrosive environment at Fort Jackson, South Carolina.

Benefits Properly monitored cathodic protection systems help prevent corrosion and alert maintenance personnel to locations with inadequate corrosion protection so that corrective action may be taken. Other benefits include extended lifetime of mission critical structures, reduced maintenance, in-creased safety, and increased operational readiness and reliability. Implementation of this project is expected to realize ULS of $14.7M. Specifications and standards will be developed for imple-mentation of this technology for similar utilities at other DoD locations.

FAR21: Sustainable Materials Replacement Purpose Renovate an existing building with sustainable material systems to document performance, eco-

nomic, and environmental benefits; develop engineering guidance documents to enable others to design and use these innovative material systems.

Technology Many commercially available, sustainable building product systems can be used in place of the more traditional material systems and are more resistant to corrosion and materials degradation. Such systems include structural insulated panel wall systems, “green” concrete, high-performance roofing, insulating additives for paints, recycled wood, recycled thermoplastic lumber, recycled carpets, bio-fiber reinforced composites, bio-based cements, hi-performance floor coatings, and synthetic exterior wall claddings.

Application A WWII-era Chapel at Fort Lewis, WA, is being transformed into an Environmental Education and Conference Center as a showcase of sustainable materials and design. A high Gold LEED (Lead-ership in Energy and Environmental Design) rating is expected.

Benefits Corrosion-resistant, sustainable material systems will reduce waste (use of products with recycled content), extend service life (more durable), reduce operational cost savings (more efficient energy usage and reduced maintenance), reduce lifecycle costs, and increase quality of life. Given appli-cations of the sustainable technologies in needed future building renovations for troop expansion, this project is expected to generate total useful life savings of $16M at Fort Lewis alone. Specifica-tions and standards will be developed for implementation of these sustainable building material technologies at other DoD locations.

FNV01: Corrosion Project Utilizing IR Drop Free Sensors Purpose Develop IR drop free sensors and a corresponding inspection tool to control and maintain the ca-

thodic protection system on cross-country pipelines. The sensors will be used to determine the rate of corrosion on the pipeline system in order to validate the cathodic protection system.

Technology IR drop free sensors measure the potential of underground pipelines immediately after briefly inter-rupting the cathodic protection current. These measurements can be substantially free of the IR drop error that plagues traditional measurements made with portable reference electrodes.

Application The Guam cross-country pipeline that runs from the Tiyan Pump house to the Andersen Air Force Base Tank Farm.

Benefits Eliminating the IR drop errors will allow for accurate assessment of corrosion protection. With this accurate assessment, the risk of pipeline failure due to corrosion decreases. In addition, this new technology will decrease maintenance costs.

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FNV04: Modeling Advanced Waterfront Metallic Material Corrosion and Protection Purpose To accurately represent corrosion behavior of structures using corrosion mitigation modeling soft-

ware. Specific tasks to achieve this goal include acquiring accurate polarization data, modeling structure surfaces, validating models, and developing requirements and recommendations.

Technology Three-dimensional boundary element modeling (BEM) software accurately predicts corrosion be-havior using non-linear material polarization relationships. BEM enables analysis of specific facility corrosion issues and corrosion mitigation alternatives.

Application Currently, the plans call for utilizing BEM analysis on a Navy modular hybrid pier and underwater unexploded ordinance.

Benefits Using BEM analysis will enable increased intervals between repairs which, in turn, allows for greater operational readiness of waterfront facilities. Other benefits include reduction in construc-tion, maintenance and operation costs, and ability to assess priorities for environmental protection. Maintenance savings, due to elimination of premature failures due to inadequacy of future designs, are estimated to be $8M over 20 years.

FNV06: Wire Rope Corrosion for Guyed Antenna Towers Purpose Develop tools for inspecting guy wire ropes. Use these tools to perform baseline inspections of guy

wires in order to identify breaks, corrosion, and other damage. Develop a realistic timetable for the systematic replacement of guy wires.

Technology An electromagnetic flux leakage sensor and other inspection methods packaged on a “vehicle” that can travel along the guy wire will reliably measure and monitor guy wire corrosion over time and space. The inspection tool will ride remotely along each guy wire in order to measure the corrosive state along the full length of the wire.

Application The guy wire inspection tool and process for managing corrosion of guy wires will be applicable for all Navy very low frequency and low frequency (VLF/LF) antennas. However, this project will ini-tially implement the inspection tool and develop a replacement timetable at the Holt antenna in Australia, which has 357 guy wires.

Benefits Managing the total cost of guy wire replacement and reducing the risk of antenna collapse from corrod-ing guy wires will yield a useful life savings of $18M. Other benefits include decreased maintenance costs and improved safety for personnel tasked with operating and maintaining VLF/LF antennas.

FNV07: Solar Powered CPS Purpose Design and install a solar powered cathodic protection system that will fully and adequately protect

water and fuel distribution pipelines from corrosion. Technology This project will entail combining a straightforward impressed current cathodic protection system

with a solar-power supply and control system for the rectifier in place of the traditional AC power that is currently not readily available.

Application Underwater water utility and fuel pipelines in the eastern side of Guantanamo Bay, Cuba. Benefits Improving corrosion protection will extend pipeline service life by 20+ years. The cathodic protec-

tion system will prevent pipeline failures, which would severely hamper flight operations and per-sonnel activities and would cause environmental damage. In addition, the solar-powered system will save an estimated $6,000 of annual energy costs.

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FNV13: Ambient Temperature Cured Coatings Purpose Determine the functional parameters under which ambient temperature cured (ATC) coatings can

be used. Recommend further evaluations, application procedures, and potential non-government standard defining products for competitive purchase.

Technology ATC fluoropolymers are a generic class of coatings that start with a polyurethane resin “back-bone,” which is then fluorinated under high pressure and heat to create the modified coating resin. The resulting coating surface is easy to clean; resistant to chemicals, UV, ablation, abrasion, and impact; and will not support mold/mildew growth. The coating has the potential to dramatically im-prove the long-term durability of exposed coatings and provide extended substrate preservation.

Application All Navy and Marine Corps facilities especially exterior steel and interior fuel tanks. Benefits ATC surface coatings prevent oxidation and corrosion; reduce operation, maintenance, and re-

placement costs; and extend the life of the asset. Reducing the maintenance costs on just 1 percent of the total Navy assets could result in an annual cost avoidance of $36M.

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Appendix D Summaries—FY2007 Funded Projects

The following sections provide additional information on each of the approved weapon sys-tems and equipment and facilities and infrastructure FY2007 projects.

Weapon Systems and Equipment

W07AR04: Service Life Prediction Test Purpose Provide for an improved paint specification method for assessing corrosion/degradation that better

replicates the actual environmental conditions under which fielded materiel is exposed. Technology The Army Research Laboratory (ARL) proposes to assess a cyclic weathering test that combines

accelerated corrosion and accelerated ultra violet (UV) degradation. Test results obtained will be then compared and correlated to those generated through normal outdoor exposure. The ultimate goal would be to include the accelerated corrosion/degradation test in the Army’s paint specifications.

Application Implementation will be executed through the Army’s specifications and standards office which will insert all changes and requirements into the applicable military specifications. Additionally, any data or knowledge acquired will support future Army and DoD efforts.

Benefits Benefits would be a robust protocol and methodology to evaluate new materials in a timely and reliable manner. Detailed and definitive life cycle cost models for coatings systems would be es-tablished. In addition, a Qualified Products List (QPL) of vendors who meet or exceed life expec-tancies for their respective coating systems would be established which will better assist program managers with prediction of life cycle cost for their assets.

W07AR06: Antimicrobial Mildew Growth/Bio-Corrosion Program Purpose To demonstrate the equivalence and replacement potential of RO-591 to aqueous based copper 8

for prevention of bio-corrosion in cotton webbing. The project will optimize the RO-59 coating for-mulation and applications process for the textile application. This will be accomplished by a col-laborative effort of the Army’s Soldier Systems Center (Natick), RO-59 Inc., and cotton webbing manufacturer personnel and will quantify performance of the coating and establish application pro-cedures and quality control methods. The proposed program will be carried out in two phases.

Technology Microorganism penetration studies will be performed to determine the optimum RO-59 coating levels needed to maintain 80 percent fabric strength as specified by the military standard AATCC 30-1999.

Application The anticipated outcome of this effort will be new processes/procedures for the use of an alterna-tive to the copper 8 coating system, now in use for protection against material bio-degradation, with an environmentally approved coating system, RO-59.

Benefits These results will positively impact shelter systems and parachutes, and will benefit manufacturers of truck covers, helmets, tarpaulins and uniform web gear systems. Military specifications ex-pected to be impacted include: Mil-W-530, Mil-W-5665, Mil-W-43668, Mil-T-43566, CCC-C-419, Mil-C-10859. Results indicative of success should demonstrate that alternate RO-59 coating tech-nology is equivalent or better than the copper 8 coating used currently. The optimum level of con-centration of RO-59 will be identified for each of the cotton webbing mil specifications.

1 RO-59, according to its manufacturer (RO-59 Incorporated), is a bonded lubricant coating that combines the

durability advantages of bonding with lubrication properties of polytetrafluoroethylene (PTFE) in a water-based formula, http://www.ro59inc.com/, accessed 5/02/2007.

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W07NA03: Advanced Corrosion Preventive Compounds Purpose To deliver newly authorized and implemented corrosion preventive compounds (CPCs) that are

qualified to military specifications and standards. Technology NAVAIR has developed a new high-performance, long-lasting CPC for internal airframe and vehi-

cle applications, called Navguard. This material has the potential to be used DoD-wide on aircraft and other assets. It has exhibited superior corrosion resistance in laboratory testing and lead-the-fleet field testing, and is ready for full scale evaluation to validate its performance.

Application The potential customers for this technology include all Navy, Marine Corps, Army Aviation, and Air Force programs and aircraft. Non-aviation assets, like the Marine Corps’ Expeditionary Fighting Vehicle, are also potential users depending on the outcome of field tests. Implementation for Army Aviation and the Air Force will be coordinated through their Corrosion Program Offices and the Air Force Coatings Technology Integration Office (CTIO).

Benefits The key benefits of using Navguard are reducing the maintenance intervals for re-application of CPCs and reducing the amount of compounds used. Increased performance of CPCs will mean increased aircraft time in use and reduced corrosion repair costs, including reduced maintenance man-hours.

W07NA04: Enhanced Self-Priming Topcoat Purpose To demonstrate and validate the field performance of a newly developed “Enhanced Self-Priming

Topcoat,” or eSPT, on Naval and Marine aircraft in normal operating environments. Technology Boeing and Deft Coatings, in coordination with NAVAIR, have developed the eSPT through the

multi-year Future Naval Capabilities–Total Ownership Cost Reduction (FNC-TOC) program spon-sored by the Office of Naval Research (ONR). A production batch sample of the eSPT was deliv-ered to Patuxent River NAS in June 2006.

Application The final product of this effort will be a data package to make authorization and implementation decisions for eSPT and a commercially available, TT-P-2756-qualified coating. This data is ex-pected to be acceptable to other Services for similar implementation decisions. Results of this demonstration and validation will be used to revise the current military specification provided the eSPT yields improved performance characteristics over the SPT.

Benefits The primary benefit of the eSPT is the reduced rework cycles and maintenance for painting opera-tions. It is estimated that the repaint cycle will increase to eight years as opposed to the current cycle of three to four years.

W07NS01: Quality Assurance Tools Purpose To expand the use of the NAVSEA sponsored “QA Tool Kit.” Technology This project focuses on continued implementation of painting information systems which have

been recently developed to improve the efficiency of the QA process. These systems utilize an automated, hand-held device (e.g., a micro-PC) to gather, record, and assess the painting quality assurance data. The existing tool is currently focused on eliminating the collection of data in paper format and contains the logic to perform analyses on the data collected to ensure its compliance with specifications. Further enhancements will include logic to discern the level of concern with particular out-of-specification work practices and recommended levels of repair. The tool will also be capable of collecting specified physical data via electronic means, such as dry film thickness readings and certain environmental data.

Application The project will equip 25 coating inspectors QA Tool Kit equipment, software, and training. The project also includes: support and monitoring of the QA Tool Kit for a 6-12 month period; develop-ment of a utilization report; and written architectural guidelines which could be distributed to ven-dors wishing to interface their equipment with the QA Tool Kit.

Benefits Benefits include: a decrease in the overall duration of the maintenance and construction process; improved efficiency of the decision-making process when disputes arise; and leveraging inspection data to its fullest extent, reducing downtime associated with maintenance planning.

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W07NS02: Composite Connectors and Conduits Purpose To develop composite materials technology to address the corrosion and environmental degrada-

tion of connectors/conduits in the weather-deck environment. Also to conduct a detailed analysis of existing ship design requirements to determine the types of connectors and conduits required for various shipboard systems.

Technology The proposed program is structured to develop three alternative composite connector/conduit de-signs. The three composite connector/conduit designs are based on existing, commercially avail-able technology developed by the Air Force for use on aircraft such as the C-17. The three composite connector/conduit designs also reflect three levels of performance testing and internal approvals required for fleet implementation.

Application Once the RDT&E to qualify composite connectors/conduits for Navy service is accomplished, the actual implementation of composite connectors/conduits can be implemented in the fleet at no net increase in the normal maintenance/replacement costs by making the lower cost composite prod-ucts available in the Navy stock system.

Benefits Use of composite connectors and conduits offers benefits including the following: reduction or elimi-nation of the need for maintenance of topside electrical connectors/conduits; increased reliability of critical force-protection systems such as communication between force-protection weapons and the bridge; and improved shipboard safety by avoiding the risks of corroded metal connectors/conduits allowing seawater into electrical systems causing short circuits and circuit breaker tripping.

W07NS05: Disposal Dispensing Paint Cartridges Purpose The fleet continually faces stricter environmental rules and regulations requiring the reduction and

minimization of the paint waste stream, volatile organic compounds (VOC) solvent emissions and personnel exposure to hazardous chemicals found in Navy paints. In addition to the stricter rules and regulations, the Chief of Naval Operations’ Fleet Response Plan requires a move from time-directed maintenance to condition-based maintenance. Proposed is the use of modern ultra-high solid edge retentive plural component paints, pre-packaged into disposable cartridges by paint companies and delivered in appropriate sizes to meet the job requirement.

Technology Paints will be pre-packaged by paint companies and delivered in pre-determined sizes to meet a specific job requirement. These disposable dispensing cartridges will provide the fleet with pre-packaged marine paints in dual disposable cartridges that dispense and mix paint on demand. This technology solves a fleet Top Management Attention (TMA) applications issue for the preser-vation of sail, bilges, tanks and machinery spaces. This technology has recently been developed by the private sector and has been evaluated by the Navy submarine community.

Application The goal is to modernize paint application equipment for naval ship forces and to provide the Fleet with advanced coating technology, coupled with ease of disposal configuration, which would re-place current equipment and HAZMAT disposal methods. This will be accomplished through mod-ernized paint applicators equipped with disposable dispensing paint cartridges with easily removed applicator mixing tips.

Benefits This delivery package system will reduce the waste stream by 30 percent and improve the handling, mixing and application of coating systems. This system will provide the fleet with advanced applica-tion equipment that allows the dispensing of spray or roll paints directly from pre-loaded paint car-tridges. In addition, this system will improve the sailor’s quality of life by reducing the high cycle of coating failures and lowering personnel exposure to VOCs and hazardous chemicals found in Navy paints.

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W07NS07: Induction Heating Coatings Removal Purpose Support the utilization of the new technological Induction Heating process to develop the technol-

ogy into an alternative cost-effective technique for coatings removal. Technology The induction coating removal process, based on the results of a machine which was originally

designed to be employed for sterilization of metal surfaces in hospitals., has shown that the heat-ing process can also assist in the rapid removal of coatings by just scraping the loose paint off after a brief heating period. As a result, the original focus of developing the technology for steriliza-tion has been expanded to explore the potential use of the procedure for removal of coatings in industrial applications. This inductive heating instantly disbonds the coating at the substrate, wherein, the coating can be effectively removed either by hand or allowed to fall off under it’s own weight.

Application Technology transition will take place through the Naval Sea Systems Command. NAVSEA will be the lead technical agent for the development of quality control and assurance standards.

Benefits The proposed system applies directly to mission criticality and results in benefits including: reduction in environmental pollution; reduction in worker risk; increased productivity; and ability to effectively remove special surfaces such as non-skid and explosive liners that currently are very difficult.

W07NS08: Tank Monitoring for Ship Ballast Tanks Purpose To replace the current time-based tank and void inspection method (open, gas-free, and inspect)

with a new Tank Monitoring Systems (TMS). Technology The TMS is comprised of three major components: an instrumented zinc anode; 3 to 6 silver/silver

chloride (Ag/AgCl) reference electrodes; and a waterproof enclosed data-logger system. Application This proposal would allow the first full implementation and proof of ROI metrics for this technology

with very little technical risk. Given that these installations will require in-tank effort (such as stud welding and hardware mounting), it is anticipated that this work would be integrated into other on-going tank efforts, so as to minimize scheduling impacts.

Benefits Condition-based maintenance will avoid structural damage, prevent tank-to-tank penetrations (e.g., fuel to seawater) and will improve readiness and safety. Specific benefits include: open, gas-free inspection time reduced based on the implementation and usage of corrosion sensors; im-proved resource application as a result of conducting condition based maintenance; and reduced structural damage as the result of condition-based maintenance.

W07MC02: Fastener Materials Purpose To determine appropriate fastener materials and treatments to reduce corrosion repair costs, while con-

sidering the wide range of threaded fastener applications on combat and combat support vehicles. Technology Fastener material compatibility will be determined by electrochemical testing of the fastener and

vehicle materials. Additionally, exposure testing will be accomplished using specimens that repli-cate combinations of materials used on ground combat and combat support vehicles. The tests will use standard hardware materials that are typically used in ground vehicle applications. These may include steel hardware with zinc, black oxide, and cadmium plated finishes.

Application The primary application from this effort will be revised fastener materials and installation proce-dures to reduce corrosion of ground combat and combat support vehicles. The outcome of this work will be provided to the Corrosion Rehabilitation Facilities with changes, as necessary, to technical manuals and training programs. The USMC CPAC office (through its field representa-tives) will ensure that the developed methodology is correctly applied.

Benefits Corrosion maintenance and repair currently requires significant time and resource. Vehicles that require extensive repair reduces operational readiness. Reducing the required maintenance time per vehicle will increase asset availability.

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W07AF04: Flexible Primer Purpose The goal of this effort is to test, evaluate, and qualify a coating system utilizing a primer with

enough flexibility to maintain a barrier across seams and fasteners. Technology The polysulfide chemistry that was successfully used 20 years ago has been abandoned because

the formulation could not be modified to meet the 1998 NESHAP requirements and still maintain the desired performance. A next-generation modified epoxy primer has been developed that shows promise. This project would perform laboratory testing and potentially follow-on field testing on the modified epoxy primer that is needed before this coating could be considered qualified, approved, assigned a NSN and listed in the technical orders for use.

Application This project is a transition project. The deliverable is a qualified flexible primer that would be au-thorized by an update to the technical order. There are a number of large aircraft communities interested in the project and are waiting for qualification test and field test results in order to im-plement the product. This primer would be a material substitution for existing epoxy primers with no capital investment needed for equipment purchases or upgrades.

Benefits The primary benefits from replacing the baseline epoxy primer with the new flexible modified ep-oxy primer would be no capital investment and the resulting significant cost savings from current corrosion maintenance practices.

W07AF06: Sand Erosion Test Purpose Develop a standard sand erosion test for rotor blade protective systems utilized in a DoD-unique

military environment, specifically southwest Asia. Technology There are five essential phases to this effort: fully analyze the sand parameters unique to the theater of

operations in SW Asia; baseline the rotor blade protective systems currently utilized on DoD platforms; examine and evaluate the Air Force Research Laboratory (AFRL) Particle Erosion Test apparatus to determine testing deficiencies with current sand erosion test protocol; characterize rotor blade damage unique to platforms returning from the SW Asia theater of operations; and accomplish a preliminary test procedure V&V for classes of erosion protective systems currently used on rotor blades.

Application This product can be utilized by DoD material RDT&E organizations and original equipment manu-facturers (OEMs) for state-of-the-art (SOA) rotor blade protective system selection and transition to the warfighter. This product will also be incorporated in the Joint Test Standard for Rotorcraft Rotor Blade Protective Systems managed by the Army. It is recognized by the IPT for this effort that ro-tor blade protective systems characterization and durability to sand erosion needs to be integral with the design of future rotor blade systems.

Benefits Without an effective basic screening tool, such as what is being proposed, no means of even a minimal margin of safety for operational readiness in terms of sand erosion resistance can be measured for rotor blade protective materials. Currently, materials being transitioned to field-level testing are accepting medium to high level of risk on predicting performance and repair for a sand laden operational theater in the absence of this screening tool.

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W07AF08: Qualification and Integration of Av-DEC Antenna Gaskets on C-17 Aircraft Purpose The USAF C-17 maintainer community has requested the process for installing antennas be

changed to eliminate the use of the aerospace material specification (AMS) 3675 polysulfide seal-ing material and enable the use of gaskets under the antennas installed on the C-17 aircraft. The current use of a polysulfide sealant on external antennas has a long cure time, is environmentally unsound, can damage aircraft surfaces, and permanently stains and/or ruins uniforms. An alter-nate material, a gasket produced by Aviation Devices & Electronic Components, LLC (Av-DEC), has been requested in lieu of the current polysulfide sealant.

Technology This project supports the replacement of the currently authorized AMS 3675 sealant with a precut gas-ket made by Av-DEC. The Av-DEC gaskets consist of an aluminum wire mesh substrate encapsulated in a fully cured polyurethane based elastomer. The gasket is about 0.055 inch thick uncompressed and is cut to match the footprint or the intended antenna. The gasket also includes a matching antenna fas-tener hole pattern and will overlay the antenna base. The Av-DEC gaskets have found wide use on other commercial and military aircraft, but are not approved for use on the C-17.

Application All USAF C-17 aircraft with probable applicable to most DoD aircraft. Benefits Elimination of unscheduled antenna removals caused by corrosion; increased sortie reliability by

the reduction of antenna signal loss; and reduction of maintenance labor hours and antenna costs.

Facilities/Infrastructure Projects

F07AR01: Corrosion Resistant Non-Metallic Materials for HDS Piping Purpose Assess the thermal performance and corrosion condition of two versions of the installed new heat

distribution systems (HDS) piping design. Technology Systems with a split (i.e., “compound”) insulation approach, and a nonmetallic outer conduit shell

compound of high-density polyethylene (HDPE) or fiberglass reinforced plastic (FRP) cladding with comparable in-ground service lives will be examined at Fort Carson and at Fort Stewart for compari-son purposes. Both will be partially exposed for examination and assessment, instrumented for moni-toring for heat loss and then reburied according to manufacturers (and federal criteria) recommended practices. Conduit air pressure testing and other assessment means will also be applied.

Application The results of this work are expected to quantify the working performance of these two versions of the new HDS design for both corrosion resistance and heat loss. For the installation, this is ex-pected to provide an assessment of their direct buried HDS piping. In a larger sense, the results should influence future procurements of HDS piping within DoD.

Benefits The operational benefits of implementation of this technology for these mission critical systems are: enhanced safety, energy efficiency, and reliability for HDS systems due to reduced probability of failure, and life extension for mission-critical infrastructure and reduced maintenance and repair. Specifications and standards will be developed for implementation of nonmetallic HDS piping at other DoD locations.

F07AR03: Corrosion/Degradation Monitoring Technology for FRP Composites Purpose To condition monitor Fiber Reinforced Polymer (FRP) composite seismic upgrades at Michie Stadium

(West Point) in order to predict their long term degradation rates, based on short term non-destructive testing.

Technology Acoustic guided wave (AGW) inspection, an emerging technology for non-destructive evaluation of FRP composite materials, has been developed to indicate the relative condition of the FRP com-posite structural upgrade, and can predict the composite material’s degradation rate. The data then can be extrapolated to predict long term performance, as well as service life.

Application This technology will be implemented at Michie Stadium, USMA (West Point). It is expected that this project will show the utility of composite corrosion/degradation monitoring system as effective real-time monitors of composite patch degradation and debonding rates, allowing the prediction of lifetime composite

Benefits The benefits of implementing the sensor-based corrosion/degradation monitoring system for com-posite patch upgrades are increased service life and reduced maintenance cost. Specifications and standards will be developed for implementation of this technology for similar structures at other DoD locations.

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F07AR05: Corrosion Detection and Management System for Potable Water at Fort Drum, NY Purpose Provide a developed, full-spectrum computer-based system that can predict and manage corrosion,

and automatically deliver corrosion inhibitors as needed in potable water distribution systems. Technology The system includes a dynamic water distribution system chemical and hydraulic simulation and

diagnostic/management system that is interfaced with corrosion sensors and automated chemical injection via a Supervisory Control and Data Acquisition (SCADA) system. The system analyzes the data to provide continuous and automatic, installation-wide, automatic detection and diagnosis of corrosion and water corrosivity problems.

Application The deliverable will be a computer-based system that provides full-spectrum detection, diagnosis, management, and prevention of corrosion in potable water piping systems. The expected outcome is improved corrosion prevention and control in water distribution systems. Specifically at Fort Drum, corrosion-induced water quality problems will be eliminated. The technology is applicable to any DoD installation with a potable water distribution system, including those systems that have been privatized or are operated by contractors.

Benefits The benefits of implementation of this system are the avoidance of premature pipe and tank fail-ure, and avoidance of the resulting fire suppression system failures, mission delays, and water quality problems. Proper water quality will enable the distribution system to meet or exceed its planned service life of 50 to 75 years, instead of requiring replacement due to corrosion failure in 20 years. It will also help DoD installations meet the requirements of the Safe Drinking Water Act. The technology has a dual benefit in that it improves water distribution system security. Specifica-tions and standards will be developed for the corrosion detection and management system for potable water distribution systems at other DoD locations.

F07AR07: Advanced Acoustic Leak Detection Purpose To demonstrate a low cost tool to detect corrosion induced leaks in critical portions of fuel distribu-

tion piping systems. Technology This project is an extension of a new application of a technology originally designed to work with

water carrier systems: the different acoustic and hydrodynamic properties of the fluids in the sys-tem will need to be determined and programmed into the leak detection algorithm in order for the system to function accurately. The installed sensors will listen for leaks and will transmit a leak status to the collection unit.

Application This project will demonstrate a passive acoustic leak detection system that will be permanently in-stalled at Fort Carson. The detection equipment will listen for fuel system leaks in approximately 20 critical locations. Training will also be provided to installation personnel on the use of the system.

Benefits The operational benefits of implementation of this technology for these mission critical systems include enhanced safety and reliability of the fuel distribution systems, due to increased system integrity and awareness. The implementation of leak detection technology reduces maintenance required, and is expected to increase the longevity of these mission critical systems. Specifications and standards will be developed for implementation of the advanced leak detection systems for fuel and water distribution systems at other DoD locations.

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F07AR08: Rehabilitation of Metal Roofing Purpose Application of the roofing rehabilitation system will reduce maintenance to buildings, such as avia-

tion hangars, and preclude damage to the aircraft, support equipment and spare parts within the buildings that would be damaged by leaking roofs.

Technology The solution to the roofing corrosion problem lies in the use of rehabilitation technology that uses roofing restoration coatings. The roofing rehabilitation coating is a single component, fast-curing polyurea compound formulated for rehabilitation of standing seam metal roofs. It has been found that 43 percent of leaking metal roofs can be saved using the innovative self-healing roofing reha-bilitation technology.

Application Buildings at Wheeler Army Airfield, Wahiawa, Hawaii. Benefits The benefits of the implementing advanced, corrosion-resistant maintenance materials for metal

roofing include restoration of the structure to its optimum operating condition, in addition to re-duced maintenance, and increased safety, increased operational readiness and reliability. Specifi-cations and standards will be developed for implementation of this metal roof restorative technology at other DoD locations.

F07AR10: Long-life Thermal Spray Coatings for Metal Structures Purpose To thermally spray two above ground fuel storage tanks (1 million gallons each) and the associ-

ated pipe fixtures at Fort Campbell, Kentucky to produce corrosion-resistant coatings of high thick-nesses and low porosity.

Technology To thermally spray molten metal onto the steel tank and associated piping in areas where the ex-isting coatings are badly degraded. These coatings are highly adherent and can protect the steel for more than 25 years. Two different types of spray coatings will be used: Ethylene Acrylic Acid (EAA) polymeric coating on the piping fixtures, and zinc-aluminum alloy with a seal-coat on the fuel storage tank itself. EAA is a new polymeric powder that can be applied rapidly to high thick-nesses (10 to 20 mils) by thermal spraying. A new polymeric seal coat (aromatic moisture-cure urethane) will be applied on top of the zinc-aluminum alloy that is thermally sprayed onto the fuel storage tank in order to close off pores and prevent the migration of moisture and corrosive ions to the underlying metal (substrate).

Application This technology implementation at Fort Campbell will serve as test program for metallizing fuel tanks and other structures. The results will be transferred to develop guidance and standards for use of metallizing tanks and other structures at other locations, and under varying conditions. This corrosion prevention and control technology will be implemented at multiple regions and installa-tions in the future through ACSIM and IMCOM funding.

Benefits Benefits of implementing the thermally sprayed coatings for above-ground fuel tanks and associ-ated piping include restoration of the central heating plant reserve fuel tank to its optimum condi-tion, in addition to reduced maintenance, and increased safety, increased operational readiness and reliability. Based on the past record of demonstrating these technologies, it is anticipated that the thermal spray coatings will provide excellent corrosion protection and prevent the fuel tank from leaking for another 30 years. Specifications and standards will be developed for implementation of these thermally-applied, corrosion-resistant coatings for metal structures at other DoD locations.

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F07AR15: Advanced Corrosion Resistant Steel for Fire Suppression Pipeline Rehab Purpose Implement innovative corrosion-resistant steel for the rehabilitation of critical utility systems such

as fire suppression system pipelines. Technology Judiciously chosen stainless steels, and innovative new steels (for example, a patented new proc-

essing technology called “Linterprocessing”) creates steel pipe with integral diffuse protective lay-ers for superior corrosion resistant properties compared to regular carbon steel.

Application Fire suppression pipeline for Chinuwa-1 Fuel Tank Farm at Okinawa, Japan. Benefits The benefits of the implementing the corrosion-resistant steel pipe for the rehabilitation of fire sup-

pression systems includes increased safety and increased operational readiness and reliability. These corrosion resistant steel are expected to have superior performance compared to more expensive stainless steels in many military and commercial applications as well as a lower lifecy-cle cost compared to low-carbon steel. Specifications and standards will be developed for imple-mentation of this innovative steel technology for similar application at other DoD locations.

F07AR17: Insitu Pipe Coating Technology for Fire Suppression System Purpose Corrosion in the plumbing of fire suppression systems—particularly the systems in aircraft han-

gars—is of significant concern. The five hangars at Fort Drum (New York) use the required three percent Aqueous Film Forming Foam (AFFF) system which is highly corrosive. Currently, some of the fire suppression capabilities in some of the hangar bays are not fully functional.

Technology This project will use a liquid epoxy coating to line the interior of the fire suppression pipes in the fire suppression system in the hangars at Fort Drum with the worst problem. A two part liquid ep-oxy will be injected through the system using high pressure air which coats the pipes with a 100 percent solid durable, impermeable polymer to a minimum thickness of 7-9 mils. The coating, which is resistant to aggressive water and chemicals, coats the pipe, filling pinholes and corrosion pits, while reinforcing weakened areas of pipe and reducing hydraulic drag.

Application It is the intent of the Project Management Plan (PMP) to implement this corrosion prevention and control technology at multiple Army regions and installations in the future, as well as to other Ser-vice sites.

Benefits This project has the potential for far-reaching impact across the Army and the other Services, as similar corrosion problems are present throughout DoD.

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F07AR19: Inherently Conductive Additives for Reducing Zinc Dust Content Purpose To apply a cathodic corrosion control coating on the exterior surfaces of a 300,000 gallon

(42 ft. diameter) elevated water storage tank at Fort Bragg, North Carolina. Technology The Catize™ and CarbOne™ materials are available and can readily be incorporated into epoxy paint

formulations as a replacement for zinc dust. Overall these technologies can be classified as emerging technologies with breakthrough potential. The capability exists for key improvements to performance, cost, and environmental impact with the potential to replace many coating systems currently employed. Currently these products are available in controlled commercial and development quantities. The inher-ently conductive polymer (ICP) and sacrificial metal additive system is in the early stages of commer-cialization with large-scale production offered. Single-wall carbon nanotubes (SWNT) and sacrificial metal additives are in the late stages of development with production quantities anticipated in 2007.

Application The goals of the project are: improving the reliability and reducing the cost of operating and main-taining steel structures by using cathodic corrosion control coatings. The objective is proper design and application of a protective coating system that protects steel through cathodic protection.

Benefits Based on the past record of laboratory and field testing similar technologies at Army installations, ad-vanced corrosion inhibiting coating systems would provide the benefits of application at a lower cost than traditional paint systems, and extended service life of the selected structures, as well as reduced mainte-nance and increased reliability and safety. Specifications and standards will be developed for implemen-tation of these conductive coating additives as a replacement of zinc-dust at other DoD locations.

F07NV03: Concrete Corrosion Inhibitors Purpose Determine the fundamental influence of commercial inhibitors on corrosion behavior of steel reinforce-

ment in environments typical of the chemistry of marine concrete in different stages of deterioration. Technology Measurement of the electrochemical (anodic and cathodic) current flow of corrosion cells which

develop or are inhibited in concrete environments will provide a direct measure of the effective-ness of inhibitors under evaluation for concrete repair. The performance of “conventional” corro-sion inhibitors in conjunction with newly developed inhibitor products for concrete reinforcement repairs will be approached in three phases: determining the fundamental influence of inhibitors on the behavior of reinforcement in environments typical of the chemistry of marine concrete in differ-ent stages of deterioration; evaluation of corrosion macro-cell development due to inhibitors and to environmental inhomogeneities; and inclusion of promising inhibitors in on-going waterfront rein-forced concrete repair projects.

Application The results will directly impact practices in use for concrete repairs, overlays, and rehabilitation projects. The information developed and data obtained through this project will be used to support the delivery of innovative solutions to mitigate corrosion of the waterfront infrastructure through the waterfront subject matter expert (SME) programs.

Benefits The operational benefits of implementation of this technology (in addition to cost savings included in ROI calculations for the specific projects) include longer intervals between repairs, allowing greater operational readiness of waterfront facilities and reduction in construction, maintenance and operation costs.

F07NV04: Navy Remote Monitoring Unit Purpose To install and demonstrate the effectiveness of recently developed cathodic protection system

(CPS) rectifier remote monitoring units (RMU) utilizing satellite data transmission. Technology The project will install and demonstrate the effectiveness of recently developed CPS RMUs utiliz-

ing satellite data transmission for the fuel storage and distribution CPS located in Guam to verify the ability to receive the information from this remote region. The project will consist of determin-ing/designing the installation requirements at each of the CPS units and subsequent procurement and installation of the RMUs.

Application Successful implementation of this technology in Guam will validate its transition for use on other Navy and DoD installations, as well as other critical facilities that utilize cathodic protection sys-tems. Such facilities include waterfront structures, potable water tanks, and utility piping.

Benefits The results of this project will be beneficial for future use by the Navy, as well as Tri-service instal-lation management infrastructure personnel when planning and designing cathodic protection pro-jects for maintainability in order to realize long term facility life at reduced maintenance costs.

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F07NV07: Stainless Steel Reinforcing for Concrete Structures Purpose Determine constructability and long term performance by using candidate stainless steel reinforcing

materials in a working marine concrete structure repair project and installing them in new construction. Technology The project will be accomplished in two phases—development and implementation. The development

phase will consist of comparing the lower cost corrosion resistant materials with austenitic stainless steel 316 and the commonly used duplex grade 2205. The installation phase will consist of installing top performing alloys into a waterfront facility repair project or new construction. The plans call for one pier repair and one section of new construction to contain the candidate reinforcing materials.

Application Implementation of this project as part of a major pier repair project in Pearl Harbor, Hawaii, will help gauge the effectiveness of affordable corrosion resistant reinforcing. The return-on-investment will be validated by comparing current materials associated life cycle costs with the more corrosion resistant lower grade stainless steels to provide a materials selection option in highly corrosive environments.

Benefits The benefits of this project will extend the life of the pier and reduce its life cycle costs, by reducing the recurrence of corrosion in repaired areas from about a 6 year average to 20 years. In addition to enhanced mission performance this project will significantly increase operational safety.

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Appendix E Abbreviations

AAF Army Air Field

AAIPT Aging Aircraft Integrated Product Team

ACSIM Assistant Chief of Staff for Installation Management (U.S. Army)

ADSIL Ambient Temperature–Cured Coatings

AF Air Force

AFB Air Force base

AFFF Aqueous Film Forming System

AFRL Air Force Research Laboratory

Ag-AgCl silver-silver chloride (reference electrode)

AGW acoustic guided wave

Al-BMI aluminum bismaleimide

ALC Air Logistics Center

AMCOM Aviation and Missile Command (U.S. Army)

AMMTIAC Advanced Materials, Manufacturing and Testing Information Analysis Center (formerly the Advanced Materials and Processes Technology Information Analysis Center or AMPTIAC)

AMS aerospace material specification

ANG Air National Guard

API American Petroleum Institute

AR Army Regulation

ARL Army Research Laboratory

ASP Administrative Storage Program

ASSIST Acquisition Streamlining and Standardization Information System

E-1

AT&L Acquisition, Technology and Logistics

ATC ambient temperature cured (coatings)

AvDEC® Aviation Devices (and Electrical Components)

BDE brigade

CARC chemical agent resistant coating (paint)

CDA corrosion detection algorithm

CEES cumulative environmental exposure sensors

CERL Construction Engineering Research Laboratory (U.S. Army)

CFFT Corrosion Fleet Focus Team

CG guided missile cruiser (U.S. Navy)

CMO Corrosion Management Office

CND cannot duplicate

CNO Chief of Naval Operations

CNRH Commander Naval Region Hawaii

COE Corps of Engineers

COTS commercial off-the-shelf

CP cathodic prevention (or protection)

CP&CO Corrosion Prevention and Control Overview (course)

CPAC corrosion prevention and control

CPAT Corrosion Prevention Advisory Team

CPC corrosion prevention and control

CPC IPT Corrosion Prevention and Control Integrated Product Team

CPCs corrosion preventive compounds

CPS cathodic protection system

E-2

CSG Corrosion Staging Group

CTIO Coatings Technology Integration Office

CV carrier vessel (U.S. Navy)

CVN carrier vessel, nuclear (U.S. Navy)

CVWF central vehicle wash facility

DAB Defense Acquisition Board

DAU Defense Acquisition University

DDRE Director Defense Research and Engineering

DEM/VAL demonstration and validation

DFARS Defense Federal Acquisition Regulation Supplement

DFT dry film thickness

DIEGME di-ethylene glycol monomethyl ether

DLM distance learning module

DOC Department of Commerce

DoDI Department of Defense Instruction

DOE Department of Energy

DOT Department of Transportation

DPG Defense Planning Guidance

DROLS Defense RDT&E On-Line System

DSB Defense Science Board

DTIC Defense Technical Information Center

DTL Detail specification (as in MIL-DTL)

DUSD Deputy Under Secretary of Defense

ECD estimated completion date

E-3

EEA ethylene acrylic acid

EMI/EMP electromagnetic interference/electromagnetic pulse

EOP electro-osmotic pulse

ERDC Engineer Research and Development Center (U.S. Army)

ESTCP Environmental Security Technology Certification Program

eSTP Enhanced Self-Priming Topcoat

ESWBS expanded ships work breakdown structure

FNC-TOC Future Naval Capabilities-Total Ownership Cost (reduction)

FRP fiber reinforced polymer

FY fiscal year

FYDP Future Years Defense Program

GAO Government Accountability Office

GSA General Services Administration

HAP hazardous air pollutant

HAZMAT hazardous material

HDBK handbook

HDPE high density polyethylene

HDS heat distribution systems

HEPA high efficiency particulate air

HMMWV high mobility multi-purpose wheeled vehicle

ICCP impressed current cathodic protection

ICP inherently conductive polymer

ILI inline inspection

IPT integrated product team

E-4

IRAC interim rapid action change

IVHM Integrated Vehicle Health Monitoring

JACG Joint Aeronautical Commanders Group

JCAA Joint Council on Aging Aircraft

JCAA-CSG Joint Council on Aging Aircraft—Corrosion Steering Group

JG job guide

JTP Joint Test Protocol

LAM liquid active media

LHA amphibious assault ship (general purpose) (U.S. Navy)

LHD amphibious assault ship (multi-purpose) (U.S. Navy)

LPD amphibious transport/landing dock (U.S. Navy)

LRU line replaceable unit

LSD landing ship dock (U.S. Navy)

M&P materials and processes

MAJCOM major command (U.S. Air Force)

MAUS Mobile Automated Scanner

MCAS Marine Corps Air Station

MCBH Marine Corps Base Hawaii

MEF Marine Expeditionary Force

MFSOV main fuel shut-off valve

MIL military specification, e.g., MIL-DTL (detail specification) and MIL-PRF (performance-based specification)

MIOX mixed oxidant

MSC Military Sealift Command

MTBF mean time between failures

E-5

MURI Multidisciplinary University Research Initiative

NACE National Association of Corrosion Engineers

NADEP naval aviation depot (U.S. Navy)

NAS naval air station

NASA National Aeronautics and Space Administration

NATOPS Naval Aviation Training and Operating Procedures Standardization

NAVAIR Naval Air Systems Command

NAVSEA Naval Sea Systems Command

NDAA National Defense Authorization Act

NDE nondestructive evaluation

NDT nondestructive test; nondestructive testing

NESHAP National Emission Standards for Hazardous Air Pollutants (U.S. EPA)

NSN national stock number

NSY naval shipyard

O&M operations and maintenance

OEF Operation Enduring Freedom

OEM original equipment manufacturer

OIF Operation Iraqi Freedom

OMB Office of Management and Budget

ONR Office of Naval Research

OPTEMPO operations tempo

OSD Office of the Secretary of Defense

OSHA Occupational Safety and Health Administration

OUSD Office of the Under Secretary of Defense

E-6

PBD Program Budget Decision

PDUSD Principal Deputy Under Secretary of Defense

PMO program management office

PMP Project Management Plan

POC point of contact

POL petroleum, oil, and lubricants

PPBE planning, programming, budgeting, and execution

PRCRP Pacific Rim Corrosion Research Program

PTO Pacific Theater of Operations

QA quality assurance

QML Qualified Manufacturers List

QPL Qualified Products List

R&D research and development

RDT&E research, development, test, and evaluation

Re-TOK Re-test OK

RH relative humidity

RMU remote monitoring unit

ROI return on investment

S&T science and technology

SA/CPO Special Assistant for Corrosion Policy and Oversight

SBIR Small Business Innovation Research

SCADA Supervisory Control And Data Automation (or Acquisition)

SERDP Strategic Environmental Research and Development Program

SME subject matter expert

E-7

SOA state of the art

SOAR Special Operations Aviation Regiment (U.S. Army)

SSPC Society for Protective Coatings (formerly Steel Structures Painting Council)

SSQP specifications, standards, and qualification process

TCDA topside corrosion detection algorithm

TMA top management attention

TMS tank monitoring systems

TO technical order

UFC unified facilities criteria

ULS useful life savings

USAF United States Air Force

USC United States Code

USCG United States Coast Guard

USD Under Secretary of Defense

USMC United States Marine Corps

UV ultraviolet

VLF/LF very low frequency/low frequency

VOC volatile organic compound

WBS work breakdown structure

WIPT working integrated product team

WTP water treatment plant

WUC work unit code

WWTP waste water treatment plant

E-8