Direct Maintenance Cost of Corrosion for the USAF

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Direct Maintenance Cost of Corrosion for the
USAF
Mr. Richard Kinzie USAF Corrosion Prevention and
Control Office
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Cost of Corrosion Report and Analysis

• Three studies have been done (1990, 1997, 2001)
• Goal of determining the Total Annual Direct
  Corrosion Maintenance Costs
• With each report there has been a growing
  emphasis on reporting the various cost elements
• Collection skills and field cooperation has
  increased

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Direct Corrosion Maintenance Included

• Cleaning to remove surface contaminants or to
  facilitate inspection for corrosion.
• Stripping of protective coatings (regardless of
  purpose).
• Inspection to detect corrosion or corrosion
  related damage
• Treatment of corrosion damage (corrosion removal,
  sheet metal
• or machinist work, replacement, etc.).
• Application of surface treatment (Alodine, other
  surface etch).
• Application of protective coatings (regardless of
  reason).
• Time spent gaining access to and closure from
  parts requiring any of the above activities.
• Preparation and clean-up activities associated
  with any of the above.

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Direct Corrosion Maintenance Excluded

• The cost of training personnel in corrosion
  control maintenance.
• The cost of constructing and maintaining
  facilities for performing corrosion maintenance.
• The cost of aircraft downtime associated with
  corrosion maintenance.
• The added initial cost of obtaining aircraft with
  corrosion resistant systems installed.
• The cost of maintaining a technical and
  engineering work force well trained in corrosion
  prevention and control techniques and processes.
• The cost of RD efforts related to corrosion
  prevention and control.
• A significant number of management positions
  throughout the Acquisition Centers and the Air
  Logistics Centers are provided in support of
  corrosion control maintenance these indirect
  personnel are not included.
• RP and RPIE
• Classified Systems

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Total Corrosion Costs Comparison, FY 01s
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Total Corrosion Costs and USAF OM Budget(s)
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Chart of AF OM Budget vs. Total Annual
Corrosion Costs
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Weapon System Fleet Costs
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Fleet Cost Comparison Study to Study (only
those fleets active in 01)
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Trend Lines of Fleet Aircraft Costs, 01 s
(thousands)(removing the fleets which are active
in 01 but with drastic force structure changes)
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Per Aircraft Costs, FY01 s
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Per Aircraft Costs, all fleets, FY01 dollars,
(thousands)
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Large Aircraft per Aircraft Costs, 01 s
(thousands)
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Large Aircraft Per Aircraft Costs, 01 s
(thousands) with individual trend lines
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Fighter and Attack per Aircraft Costs, 01 s
(thousands)
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Fighter and Attack Per Aircraft Costs, 01 s
(thousands) with individual trend lines
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Total Command Corrosion Costs

•  

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Total Command Corrosion Costs
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Paint Costs by Command
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Depot Totals
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Depot Costs
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Depot Costs Detailed by Category
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Other Observations
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Results and Conclusions

• Total Direct Maintenance Cost of Corrosion in the
  USAF in 2001 was 1.139 Billion
• Depot consumed 73 of 2001 corrosion maintenance
  dollars
• From 1990 to 2001 corrosion costs grew by more
  than 25 above the cost of inflation
• Corrosion Prevention Activities consumed 27 of
  the 2001 corrosion maintenance dollars
• Only 20 of the total corrosion maintenance cost
  was available via any automated data systems
• Majcom corrosion costs were 125 higher than that
  reported in REMIS