Date: 201506
Local time of day: 1201-1800
Location: ZZZ.Airport, US
Aircraft: Citation Excel (C560XL)
Operator: Fractional
Operating under: Part 135
Flight phase: Parked
Aircraft component: Fuselage Skin
Reporter organization: Fractional
Reporter function: Captain
Reporter qualification: Flight Crew Air Transport Pilot (ATP)
Human factors: Training / Qualification; Confusion; Communication Breakdown
Anomaly: Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural FAR
Detector: Person Flight Crew
When detected: Aircraft In Service At Gate
Result: General Maintenance Action; General Flight Cancelled / Delayed
Contributing factors: Aircraft; Company Policy; Human Factors
Primary problem: Human Factors

Narrative: June 2015; we found numerous corroded fasteners on numerous areas of the aircraft during the preflight of the assigned aircraft. We submitted 14 associated Logbook Maintenance Discrepancy forms to Maintenance Control. It turns out that a grand total of 920 fasteners on the aircraft were found to be corroded -- to include fasteners on the wing structure. Later on in the afternoon; the Company wanted us to fly the aircraft on a Special Ferry Permit (SFP) from Airport ZZZ to ZZZ1. An Aircraft Maintenance Technician (AMT) employed by a Regional Operator inspected and released the aircraft for a SFP flight. However; the Company was not able to provide us with a valid SFP prior to the end of our duty day. It seems the first SFP was not a valid one.The following day; we were again assigned to fly the aircraft on a Special Ferry Permit from Airport ZZZ to ZZZ1. However; the Company had to provide us with a grand total of three amendments to the provided SFP prior to receiving a valid one. The first SFP of that day did not have reference to all the open maintenance discrepancy items; the second SFP had the wrong destination airport; and the third finally was a valid SFP.Especially with the 'self-release' authority the Company has -- i.e. the authority to create SFPs without FAA involvement -- the Quality Control (QC) for this case was severely lacking. What kind of QC structure does our Operator employ to ensure regulatory compliance? What kind of training do company flight crews receive in order to ascertain a valid SFP is received? How many company crews would have accepted the first SFP provided without knowing they have not been in regulatory compliance? Airline Transport Pilot.Upon further inspection by a qualified AMT it seems that a grand total of 920 corroded fasteners were found on the aircraft -- to include fasteners on the wing structure. How does an aircraft pass routine and so-called Preventative Maintenance Inspections with a grand total of 920 corroded fasteners?What kind of guidance does the Company plan provide flight crews and Maintenance personnel in putting emphasis on corrosion detection; and even more important; reporting?

Callback: Reporter stated most of the corroded fasteners were on the underside of both wings at the wing access panels. Others were at the wing leading edge where the heated leading edge met the inboard section of leading edge; on the lower fuselage under the wing center box section; and around the cabin windows.Reporter stated he doesn't understand how their aircraft can go through Heavy C-Checks at domestic Repair Stations they contract out to and have A-Checks accomplished by their own Maintenance personnel ; yet not have these corroded fasteners noticed. Numerous complaints have also been reported to their company management about the poor quality of paint applied to their CE-560XL aircraft by a contracted paint facility.



Synopsis: A Captain files two reports about maintenance discrepancies he found during a walk around on a company Cessna CE-560XL. The aircraft had a grand total of 920 corroded fasteners on the lower surface of both wings; wing leading edges; lower fuselage skin of the wing center box section; and around the cabin windows. Pilot questions how that much corrosion could be missed after Heavy C-Checks and numerous A-Checks had been accomplished. Aircraft required Special Ferry Permit (SFP) to a repair facility.