The USA’s Mine-Resistant, Ambush Protected (MRAP) program has been a long road for BAE Systems. In the wake of the US Army’s belated realization that mine protection was critical for vehicles in theater, BAE’s designs, long-standing experience in the field, and production capacity had made them an early favorite. Early results were a deeply humbling experience for the firm, but a combination of acquisitions, persistence, and product evelopment combined to recover 2nd place status by the time MRAP orders ceased.

This in-depth, updated DID feature shines a spotlight on BAE Systems’ family of MRAP offerings, order record, and associated contracts. The MRAP program appears to have reached its vehicle limit, but some BAE vehicles are getting a major suspension upgrade and maintenance contracts continue…

• BAE MRAP: The Vehicles
• BAE MRAP: The Current Tally
• BAE MRAP: Contracts & Key Events [updated]
• Appendix A: MRAP Competition Half-Time Update, June 28/07

BAE MRAP: The Vehicles

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The RG-33L’s unique features make it a very strong contender for Explosive Ordnance Disposal roles, route-proving, and other classic MRAP Category II tasks that need a larger vehicle. It is a 6×6 vehicle designed to maximize interior space and visibility, while remaining well-protected and transportable by C-130 Hercules. At 38,700 pounds empty, it’s a close fit, and a fully-loaded vehicle can weigh up to 58,000 pounds. Compare this with an up-armored Hummer’s 9,000 pound empty weight and 12,000 pound total weight when fully loaded.

The optional robotic arm is probably the RG-33L’s most recognizable feature, allowing it to probe, remove, and/or place destruction charges near possible land mines from a safe distance. This feature helped the vehicle win the US Army’s 2,500 vehicle MMPV competition to equip its engineer and EOD (Explosive Ordnance Disposal) units. It can be fielded without the arm, and some variants like the RG-33L MEDEVAC Ambulance variant are never equipped with it.

The RG-33L’s standard armor is designed to offer protection up to medium machine gun fire, while its monocoque v-hull is designed to deflect blasts away from the vehicle offer protection against IED land mines. Its windows use TRAPP transparent armor, and the vehicle is equipped to handle the weight of additional tailored armor packages if desired. It is also equipped with run-flat tires, multi-positional mine protected seating, and other survivability equipment such as extinguishers.

An hydraulic ramp, a transparent armor gunner’s shield, dedicated space for equipment stowage, and enough power generation to operate mission electronics and air conditioning round out the RG-33L’s key features. That last item may seem like a luxury, but when it’s 110 degrees outside the vehicle and you’re wearing body armor or a full explosives protection suit, air conditioning is necessary in order to arrive in a fit state to perform one’s duties… like defusing touchy explosives. The vehicle can carry up to 14 people, including the driver & front seat.

The shorter 4×4 RG-33 has 90% commonality with its larger cousin, and is the same width and height, but loses the robotic arm. It weighs 29,700 pounds empty, with a maximum weight fully loaded of up to 38,000 pounds. They are BAE’s high-end Category I patrol vehicle offering, designed to carry up to 8 people. They are also used in reconnaissance roles, and have been equipped with hydraulic masts that carry electro-optical long-range surveillance/ infrared/ laser-targeting turrets. A special variant of the RG-33 serves with US Special Operations Command as their MRAP vehicle of choice.

BAE’s 40-ton MRRMV recovery vehicle is also based on the RG-33. As militaries internalize the need for mine-protection on combat vehicles, a couple of corollaries become obvious. One is that heavier blast-resistant vehicles need heavy wheeled recovery vehicles that can tow them out of mud, canals, et. al. – or haul a vehicle that has had an axle destroyed by land mines back to base. The other corollary is that recovery vehicles intended to work in in areas where land mines are a common weapon of war must also be blast-resistant.

The privately-developed MRRMV carries a 2-man crew, plus equipment and spare parts to conduct on-site vehicle repairs, including field maintenance tasks that require lifting, welding, cutting and heating. It also maintains space to carry 2 recovered crew, and other combat spares. The MRRMV is capable of up-righting, winching and towing Hummers and M1117 ASVs, plus all MRAP, MMPV and Stryker class vehicles. Indeed, BAE claims that it has the capacity to recover all types of U.S. tracked and wheeled combat vehicles, with the exception of M1 Abrams battle tanks and the M88 Hercules tracked recovery vehicle.

BAE’s new subsidiary Armor Holdings was offering the Caiman MRAP vehicle before the acquisition, and is now known as BAE Tactical Vehicle Systems (BAE-TVS). Caiman is a v-hulled capsule design, mounted on the US Army’s standard FMTV medium trucks. This is not entirely surprising; one of the salient features of the trend toward mine-resistant vehicles is the use of truck chassis instead of standard automotive bases, in order to accommodate the extra armor and body weight associated with these kinds of vehicle designs. It also allows BAE to offer mine-protected cargo carrier versions of its vehicle in future.

Compared to the RG-33 family, the Caiman is slightly narrower (94 vs. 96 inches) and not quite as tall (111 vs. 136 inches). As a “v-capsule” design, Caiman acquires some of the classic drawbacks of easier “mobility kills” and a potentially higher center of gravity, in exchange for easier production due to commonality with the popular and successful FMTV truck that makes up the backbone of the US Army’s medium truck fleet.

While there are technically 2 types of Caiman on offer for the MRAP program, they are actually the same vehicle with different numbers of seats installed inside. A smaller Caiman version did not make it through testing, and the decision was made to use the larger CAT-II vehicle design and install fewer seats to create the CAT-I offering. Caiman vehicles can carry up to 10 soldiers, including the driver and front seat.

More Caiman variants may be on the way. BAE spokespeople have confirmed to DID that the firm’s MRAP-II vehicle contender, which was one of only 2 vehicles to pass through initial testing against a wider range of threats, is based on the Caiman platform. Moving in the other direction, the firm’s “Caiman Light” is designed to be smaller and provide more mobility in Afghanistan. A further step was taken with a Caiman M-ATV design that lightens the vehicle further and lengthens its nose to provide better balance for all-terrain mobility, but reduces the number of troops that can be carried.

BAE MRAP: The Current Tally

Despite their status as early favorites, by June 20/07 contracts had been issued for 3,266 Category I patrol & Category II squad-sized MRAP vehicles, fully 42% of a the program’s planned 7,774 orders. Force Protection had racked up orders for 1,780 Cougar vehicles, and Navistar/Plasan Sasa had come out of the tests at Aberdeen with orders for 1,216 of its MaxxPro joint design. BAE sat in 4th place with orders for just 90 vehicles – 2.8% of the total. It had to be a humbling experience for the firm that went into 2004 as the world leader in the field.

BAE has worked hard to catch up, even as the number of MRAPs in the program more than doubled to over 15,000. The final tally gave them a wide 2nd place lead over 3rd place firm Force Protection. It also made them one of just 2 firms with a foothold under new MRAP-II qualifications, which includes protection against EFP (explosively-formed projectile) land mines that fire the equivalent of a cannon shell at the vehicle, in addition to the standard under-body blasts.

As of December 2007, more than 2,000 BAE Systems employees in the United States and 400 in South Africa (BAE OMC, producing General Dynamics’ entry) are producing vehicles with the support of suppliers in more than 30 states across the United States. Key production locations include York, PA; Fairfield, OH; Aiken, SC, and Sealy, TX, with production assistance from partners Spartan Motors Chassis and Demmer Corporation.

Of the envisaged 15,771 vehicles in the MRAP-I program as of March 31/08, all have now been ordered. Orders continue to be placed under the original MRAP vehicle solicitation until production verification of vehicles presented for testing in response to the MRAP II solicitation is completed, or an interim buy is approved. Thus far, BAE has directly received MRAP contract orders to date for 5,120 vehicles:

• 369 RG-33 MRAP CAT-I and SOCOM variants
• 1,710 RG-33L (MRAP CAT-II w. optional robotic arm)
• 179 RG-33L MEDEVAC Ambulance variant
• 2,178 BAE-TVS Caimans, CAT-I seating internally
• 684 BAE-TVS Caimans, CAT-II seating internally

Based on these orders, BAE remains 2nd place in the MRAP CAT-I/II race, with 32.4% of all orders to date. This is a major improvement from its position earlier in the competition, and its own high-end RG-33 vehicles now own a respectable 14.3% share. The leader is still Navistar with 38.3%, a lead that widened recently when its lighter “MaxxPro Dash” was selected by the US Army in a recent order for the Afghan theater. One-time leader Force Protection has slipped to a distant 3rd place at 19.5% and is unlikely to receive further MRAP orders.

General Dynamics Land Systems has also been contracted to supply 10 RG-31 Mk5 CAT I and 1,383 RG-31E Mk5 CAT II MRAP vehicles to the US military, in partnership with the Canadian government and BAE OMC of South Africa. These are not included in the above figures. If they are counted, BAE’s MRAP share rises to 41.3%, giving the firm 1st place overall.

BAE MRAP: Contracts & Key Events

Unless otherwise noted, the Marine Corps Systems Command in Quantico, VA buys MRAP vehicles on behalf of requests from the US Army (12,000), USMC (2,225), Air Force (558), Navy (544), SOCOM (344), and production verification testing (100). The USMC reduced its requirements in the wake of their campaign’s smashing success in Iraq’s Anbar Province, and so did the Air Force, but the Army’s increased orders for use in Afghanistan and Iraq caused the overall target number to rise slightly.

Unless otherwise noted, BAE Systems Land & Armaments LP’s Ground Systems Division in York, PA is the contractor. Note that references to BAE-TVS indicate Caiman family vehicles. Delivery orders and quantities include:

RG-33 Family
#001: Testing vehicles
#002: 15 RG-33; 75 RG-33L
#003: 255 RG-33; 170 RG-33 SOCOM; 16 RG-33L Ambulance
#004: 89 RG-33 SOCOM
#005: 399 RG-33L; 112 RG-33L Ambulance
#006: 600 RG-33L with enhanced armor
#007: 3 RG-33 SOCOM; 393 RG-33L; 51 RG-33L Ambulance
#008: 40 RG-33 SOCOM
#009: 36 RG-33 SOCOM; 2 RG-33L; 2 RG-33L Ambulance – all modified designs. #010: 8 RG-33 SOCOM with modifications

Caimin Family
#001: Testing vehicles
#002: 1,154 CAT I; 16 CAT II
#003: 668 CAT II
#004: 1,024 CAT I #005: Upgrades to 1,800 vehicles

Sept 28/09: Oshkosh announces orders valued at $24 million to supply its TAK-4 independent suspension system for more than 300 BAE Systems USCS RG-33 Mine Resistant Ambush Protected (MRAP) vehicles (q.v. July 28/09 entry). The vehicles will be upgraded in theater, with work expected to be complete by March 31/10.

TAK-4 is quickly becoming a significant player in US military vehicles. Oshkosh Defense is working with multiple manufacturers of legacy MRAPs and has now received orders for more than 2,300 TAK-4 systems for the vehicles from Force Protection, BAE, and Navistar. It’s also installed on Oshkosh’s new MRAP-All Terrain Vehicle (M-ATV), the U.S. Army’s FHTV Palletized Load System (PLS A1) heavy trucks, and the U.S. Marine Corps’ Medium Tactical Vehicle Replacement (MTVR) medium trucks and Logistics Vehicle System Replacement (LVSR) heavy trucks.

Sept 04/09: BAE Systems Tactical Vehicle Systems (BAE-TVS) in Sealy, TX received a $31.2 million firm-fixed-priced modification to a previously awarded contract (M67854-07-D-5030), delivery order #0003, for the purchase of field service representatives to support training for the 1,800 vehicles procured under this contract and to upgrade the entire Caiman fleet troops seats.

The training will be performed at various locations throughout US Central Command’s area of responsibility. The period of performance is expected to be completed by Sept 30/10. The base contract was competitively awarded, and the new requirements are sole source additions to the contract.

In an effort to make the Caiman vehicles more resistant to IEDs, BAE Systems is working to improve the seat design. One improvement is to suspend the seats from the ceiling, which prevents the transfer of energy up the spine of soldiers in the vehicle if a mine explodes underneath.

Aug 06/09: $28.5 million in firm-fixed-priced modifications to previous delivery orders were awarded for MRAP vehicle field service representative (FSR) instructors, covering each set of BAE MRAPs:

BAE Systems Tactical Vehicle Systems, LLP (BAE-TVS) in Sealy, TX received an $11 million delivery order modification for FSR instructors to support training for 1,800 Caiman MRAP vehicles. The training will be performed at various locations throughout the CENTCOM area of responsibility, and the contract will expire at the end of FY 2010: Sept 30/10. The listed delivery order is (M67854-07-D-5030, #0003).

BAE Systems Land & Armaments, LP, Ground Systems Division in York, PA received an $8.9 million modification to a delivery order (M67854-07-D-5025, #0004) for OCONUS instructors to support RG-33 SOCOM vehicles. Work will be performed in Iraq and is expected to be completed by December 2009.

July 28/09: BAE Systems Land & Armaments, LP, Ground Systems Division in York, PA receives 3 firm-fixed-priced modifications to previous delivery orders, worth $96.7 million, to upgrade RG-33 SOCOM vehicles with Oshkosh’s TAK-4 independent suspension kits. Work will be performed in Operation Iraqi Freedom/ Operation Enduring Freedom areas of responsibility, and is expected to be completed by March 31/10. Contracts include:

• $52.5 million modification to delivery order #0003, to upgrade 170 vehicles.
• $28.6 million modification to delivery order #0004, to upgrade 89 vehicles.
• $15.6 million modification to delivery order #0009, to upgrade 35 vehicles.

TAK-4 suspensions give the vehicles greater off-road mobility. They are used in the US Marne Corps’ MTVR medium trucks, Oshkosh’s MRAP-ATV competition winner, and as an ongoing retrofit to over 1,300 of Force Protection’s Cougar family MRAPs.

July 27/09: BAE Systems Tactical Vehicle Systems LP in Sealy, TX received a maximum $34.1 million firm-fixed-price, sole-source contract for axle assembly parts in support of its Caimin MRAPs. Contract funds will expire at the end of the current fiscal year, on Sept 30/09, but the contract will run to March 24/11. The Defense Logistics Agency, Warren (DSCC-ZG) in Warren, I manages this contract (SPRDL1-09-C-0121).

May 18/09: BAE Systems Land & Armaments, Ground Systems Division in York, PA received a $14.3 million a firm-fixed-priced modification of a previously awarded delivery order (M67854-07-D-5025, #004), for field service representatives and instructors to support RG-33 SOCOM vehicles. BAE Systems expects to complete the work by December 2009.

May 14/09: BAE Systems Land & Armaments, Ground Systems Division in York, PA received a $7.1 million indefinite-delivery/ indefinite-quantity delivery order under a previously awarded contract (M67854-07-D-5025, #010). The delivery order buys 8 US Special Operations Command CAT I, vehicles including technical changes from the baseline RG-33 SOCOM design that have been made in light of operational experience. Work will be performed in York, PA and is expected to be complete by November 2009.

April 24/09: BAE Systems Tactical Vehicle Systems LLP (BAE-TVS) in Sealy, TX received a $19 million firm-fixed-priced modification to a previously awarded contract (M67854-07-D-5030, #0005), to buy Capability Insertion Engineering upgrades for 1,800 MRAP vehicles

Work will be performed at Kuwait Refurbishment Facility, and the final deliveries associated with this delivery order are expected to be completed by July 30/10.

April 9/09: A $47.2 million firm-fixed-priced modification to a previously awarded delivery order (M67854-07-D-5025, #006) for MRAP field service representatives and instructors in Iraq. Work is expected to be complete by the December 2009.

March 11/09: BAE Systems Tactical Vehicle Systems LLP in Sealy, TX received a $33.2 million firm-fixed-priced modification to a previously awarded contract (M67854-07-D-5030, #0003). This modification updates the unit cost for the following contract line item numbers related to their Caimin vehicles:

CLIN 0241 – Improved Front Seat – LRIP 10
CLIN 0251 – ECP 12 Pin/24V Electrical Connector for Towing
CLIN 0252 – ECP Door Assist System (DAS) Safety Strip – Retrofit

In addition, the following CLINs have been added to the contract:

CLIN 0031 – Technical Manual Verification
CLIN 0255 – MEAP Technical Bulletin
CLIN 0258 – MAMA Bear IBOM LRIP 11
CLIN 0260 – Repair Damage Vehicles at SPAWAR
CLIN 0262 – Developing CAIMAN DEMIL Procedures
CLIN 1015 – CONUS (inside the CONtinental US) Instructors
CLIN 1016 – OCONUS (Outside the CONtinental US) Instructors
CLIN 1017 – OCONUS Field Service Representatives

The Authorized Stock List Supplemental Spares parts will be delivered to SR W4GG at HQ US Army TACOM in Warren, MI and the Defense Distribution System at Red River, Texarkana, TX. Deliveries associated with this delivery order will take place after receipt of this modification. The work is expected to be complete in January 2010.

Nov 20/08: BAE Systems holds a ceremony to mark the end of Caiman MRAP production at the BAE Systems’ FMTV truck production facility in Sealy, TX. The event celebrates the 2,868th Caiman to roll off the assembly line, completing the vehicle’s 22-month production run. During that production run, Caiman was the #1 MRAP vehicle in terms of its on-time to promised delivery ratio. It also delivered to a weekly schedule, instead of the monthly schedule that was standard for a number of other vendors.

As noted below, ongoing modification and maintenance work can be expected for the existing fleet. Should MRAP-II lead to a new set of orders for EFP-resistant vehicles, production could restart as BAE’s Caiman and Oshkosh/ Ceradyne/ i3’s Bull are the 2 qualifying contenders. In the meantime, the Sealy production line will continue to build FMTV medium trucks for the US Army.

Nov 5/08: BAE Systems Land & Armaments, Ground Systems Division in York, PA received a $31.7 million firm-fixed-priced modification to a previously awarded delivery order (M67854-07-D-5025, #005) for field service representatives and instructors to support its RG-33L and RG-33L Ambulance MRAP vehicles. Work will be performed in York, PA, and is expected to be complete by January 2009.

Nov 5/08: BAE Systems Land & Armaments, Ground Systems Division in York, PA received a $8.7 million firm-fixed-priced modification to a previously awarded delivery order (M67854-07-D-5025, #004) for field service representatives and instructors to support Caimin MRAP vehicles. Work will be performed in York, PA, and is expected to be complete by January 2009.

Oct 24/08: Defense News reports that more mine-resistant vehicles could be in the order pipeline. The U.S. Army and Marine Corps reportedly plan to rapidly develop and buy a fleet of lighter 7-10 ton vehicles that offer better mine resistance than Hummers, but better off-road mobility than MRAPs. Afghanistan is seen as an especial focus for these vehicles.

Defense News places potential military demand at 2,000- 5,000 bridge buy vehicles – assuming that issues with JLTV issues don’t lead to the bridge becoming the road.

The Oshkosh/Plasan Sasa Sandcat and Force Protection’s Cheetah vehicle are seen as potential candidates for that bridge buy. Navistar’s MaxxPro must also be placed in this category, given recent the MRAP orders for deployment of their lightened MaxxPro Dash variant to Afghanistan. Iveco’s MLV is in service with many European armies, and is beginning to see front-line action; it appears to be qualified, if an American production solution can be found. BAE’s RG-33 and Caiman, however, are both too heavy, even in their Category 1 versions. Their RG-32M meets the weight requirement, but may not suffice for protection; a lightened RG-31 variant might do better, and a September 2008 R&D contract to that effect has been issued via BAE OMC’s General Dynamics/Governent of Canada partnership.

Oct 23/08: A $22.9 million firm-fixed-priced modification to previously awarded delivery order #0004 under contract (M67854-07-D-5025) for Field Service Representatives (FSR) and Instructors to support Mine Resistant Ambush Protected (MRAP) vehicles. Order #004 involved 1,024 Caiman MRAPs, derived from the Army’s FMTV medium truck.

Work will be performed in York, PA, and is expected to be complete by January 2009.

Oct 10/08: An $8 million firm-fixed-priced modification to previously awarded delivery order #0003 under a previously awarded contract (M67854-07-D-5025) for integrated logistics support to support Mine Resistant Ambush Protected (MRAP) vehicles.

See Dec 18/07 entry; that order involved 668 Caiman MRAP vehicles with the 4-passenger CAT I seating configuration. The Caimin shares substantial commonality with the Army’s standard FMTV medium trucks. Work will be performed in York, PA, and is expected to be complete by January 2009.

Oct 7/08: BAE Tactical Vehicle Systems in Sealy, TX received a $19 million firm fixed price contract for MRAP parts. Work will be performed in Humble, TX; Lufkin, TX; and Houston, TX; with an estimated completion date of Aug 5/08. One bid was solicited and one bid was received. US Army TACOM in Warren, MI manages this contract (W56HZV-09-C-0010).

Sept 26/08: U.S. Special Operations Command issues the first 3 delivery orders to Raytheon Co. in Fort Wayne, IN, under a 3-year indefinite-delivery/ indefinite-quantity contract with a ceiling of $54 million. The contract covers Multiband Multimission Radio (MBMMR) Systems, in support of the RG-31 & RG-33 SOF vehicles. The radios will be produced in Fort Wayne, IN and Largo, FL (H92222-08-D-0003). Awards under this Raytheon contract include:

• Delivery order 0001: $274,626
• Delivery order 0002: $10.8 million
• Delivery order 0003: $10.5 million, 26-month delivery order with a completion date of November 2010.

Note that other radio contracts have been issued to Harris Corp. for installation in MRAP vehicles, but specific vehicle types have not been mentioned.

Sept 22/08: An $11 million firm fixed priced modification 05 to delivery order #0006 under contract M67854-07-D-5025, for spares and sustainment items needed to support Category II MRAP vehicles in theater. Work will be performed in York, PA and the support contract will end in April 2009.

Sept 22/08: BAE Systems Land & Armaments, Ground Systems Division, York, PA is being awarded a $43.9 million firm-fixed-priced modification 03 to delivery order #0007 under previously awarded contract M67854-07-D-5025, for spares and sustainment items needed to support Category II and Heavy Armored Ground Ambulance MRAP vehicles in theater. This support contract ends in April 2009. BAE Systems release.

Sept 9/08: BAE Systems Survivability Systems, LLC in Fairfield, OH received a maximum $9.8 million fixed price with economic price adjustment, indefinite-quantity, sole-source, un-definitized bilateral contract modification for Mine Resistant Ambush Protected Vehicle Replacement (MRAP) spare parts.

Using services are Army and Marine Corps. There was originally one proposal solicited with one response. Work under this modification will end on Feb 10/09. The Defense Supply Center Columbus in Columbus, OH (SPM750-05-D-7426) manages the contract.

Aug 8/08: BAE Systems Tactical Vehicle Systems LLP (BAE-TVS) in Sealy, TX received a $318 million firm-fixed-priced modification to a previously awarded contract (M67854-07-D-5030, #0004). It covers vehicle modifications, support, and spares for the 1,024 vehicles included in that order. Work will be performed in Sealy, TX (58%) and Fairfield, OH (42%), and is expected to be complete in December 2008.

July 18/08: $60.3 million for delivery order #0009 under previously awarded firms-fixed-price, indefinite-delivery/indefinite-quantity contract (M67854-07-D-5025). It covers 36 United States Special Operations Command (USSOCOM) MRAP Category I vehicles including technical insertion engineering change proposals (ECPs), another 2 RG-33L MRAP Category II vehicles including technical insertion ECPs, and 2 RG-33L MRAP Category II Ambulance vehicles including technical insertion ECPs.

Work will be performed in York, PA, and is expected to be complete in March 2009.

May 30/08: A $162.1 million firm-fixed-priced modification to Delivery Order #0007 under previously awarded contract (M67854-07-D-5025) for engineering change proposals to modify BAE’s MRAP designs. Work will be performed in York, PA, and is expected to be complete by December 2008.

May 20/08: A $24 million firm-fixed-priced modification to previously awarded delivery order #0003 under contract (M67854-07-D-5025) for integrated logistic support sustainment to support MRAP vehicles. Work will be performed in York, PA and is expected to be complete by January 2009.

May 20/08: A $35.2 million firm-fixed-priced modification to previously awarded delivery order #0005 under contract (M67854-07-D-5025) for integrated logistic support sustainment to support MRAP vehicles. Work will be performed in York, PA and is expected to be complete by January 2009.

May 6/08: BAE Systems announces that it has received a $23.7 million contract from the Army’s Tank-Automotive and Armaments Command Life Cycle Management Command to equip 371 RG-31 vehicles and 174 MRAP-II vehicles (545 total) with its lightweight L-ROD bar-armor kits. The kits are designed to provide partial protection against anti-tank rockets, and are used widely on the US Army’s MRAP Class III Buffalo ordnance disposal vehicles. See also DID’s coverage of the LROD system, which explains how it works.

May 2/08: BAE Systems Land & Armaments’ Ground Systems Division in York, PA received a $53.2 million firm-fixed-priced delivery order under a previously awarded contract (M67854-07-D-5025, #0008) for 40 “Category I U.S. Special Operations Command armored utility variant vehicles.” BAE has confirmed to DID that these are the RG-33 4×4 SOCOM variant. Work will be performed in York, PA and is expected to be complete by February 2009.

March 20/08: BAE Systems received a U.S. Army contract worth up to $47.2 million to manufacture 65,000 Expanded Metal Armor plates, and fund tooling to establish additional production capacity at the company’s Anniston, AL facility. The contract is currently funded at $23.6 million and not to exceed $47.2 million.

The program, “developed by BAE Systems for use on future MRAP vehicles,” will add 30 jobs at the Anniston facility. BAE Systems release.

March 14/08: BAE’s Stewart & Stevenson Tactical Vehicle in Sealy, TX received a $481.8 million for firm-fixed-priced delivery order (M67854-07-D-5030, #0004) for 1,024 “Mine Resistant Ambush Protected Category (CAT) II vehicles with CAT I seating configuration.” As noted above, this is exactly what the “Caiman Category I” is. Work will be performed in Sealy, TX and is expected to be complete in November 2008.

BAE’s release adds that:

“When the additional awards are combined with previous contracts, the total value of BAE Systems’ MRAP contracts increases to $2.95 billion to build three of the five MRAP variants…. The Joint Program Office anticipates ordering approximately $174 million worth of Engineering Change Proposals (ECP) to achieve high levels of survivability with enhanced mobility. Spares and increased contractor logistic support associated with this award are also anticipated. This brings the total value of the Caiman program to $1.77 billion since the program began in early 2007.”

March 14/08: BAE Systems Land & Armaments, LP. Ground Systems Division, York, Pa., is being awarded $234,043,500 for firm-fixed-priced delivery order #0007 under previously awarded contract (M67854-07-D-5025) for the purchase of 3 Special Operations Command variants, 51 Ambulance variants, and 393 Category II variants of the Mine Resistant Ambush Protected (MRAP) vehicles. Work will be performed in York, PA, and is expected to be completed by November 2008.

Feb 19/08: BAE announces the RG-33 MRRMV recovery vehicle. The 40-ton wheeled vehicle has a 2-man crew and carries equipment and spare parts to conduct on-site vehicle repairs, including field maintenance tasks that require lifting, welding, cutting and heating. It also maintains space to carry 2 recovered crew and combat spares.

The MRRMV is capable of up-righting, winching and towing Hummers and M1117 ASVs, all MRAP, MMPV and Stryker class vehicles. Indeed, BAE claims that it has the capacity to recover all types of U.S. tracked and wheeled combat vehicles, with the exception of M1 Abrams battle tanks and the M88 Hercules tracked recovery vehicle.

Feb 18/08: BAE announces a pair of MRAP support contracts. the first is a $10.3 million modification to provide training, documentation and technical support for RG33 MRAP vehicles. A second, $11 million modification, calls for BAE Systems to provide spare parts for the vehicles. According to BAE, these modifications bring the total value of the contracts BAE Systems has been awarded on MRAP RG33 vehicles to $1.3 billion.

Dec 19/07: BAE Systems Land & Armaments Ground Systems Division in York, PA received a $10.3 million firm-fixed-priced modification under previously awarded contract (M67854-07-D-5025) for Integrated Logistic Support sustainment. Work will be performed in York, PA and is expected to be completed by Jan. 2009. This contract was competitively procured.

Dec 18/07: BAE Systems Land and Armaments LP Ground Systems in Santa Clara, CA received a $5.8 million firm-fixed-price delivery order under a previously awarded contract (M67854-08-D-5001, #0001) for MRAP-II test vehicles. Work will be performed in Sealy, TX; York, PA; and Fairfield, OH, and is expected to be complete July 2008. This contract was competitively procured, and at this point the only other winner is The Bull from Oshkosh/ Ceradyne/ I3. BAE has submitted the Caiman 6×6 as its MRAP-II CAT I entry, and the RG-33L 6×6 as its MRAP-II CAT II entry. See BAE Systems release.

The MRAP-II contracts are a developmental effort to purchase test vehicles and armor for enhanced MRAP survivability against explosively formed penetrator (EFP) land mines, and for mobility tests. The initial testing at Aberdeen served to disqualify vehicles that didn’t meet the standard. More copies of the winning test vehicles will now be delivered to Aberdeen Test Center for comprehensive testing, and the 2 MRAP-II contracts issued today also contain ordering options for production quantities under a $12.5 billion indefinite-delivery/ indefinite-quantity multiple vendor contract for up to 20,500 vehicles.

Competitors who did not receive MRAP-II orders include Force Dynamics (reinforced Cougar), GDLS Canada (upgraded BAE OMC RG-31), Navistar subsidiary IMG (upgraded MaxxPro), and Protected Vehicles, Inc. (upgraded Golan vehicle, with improved side doors and different armor; arrived on last day). Note that the MRAP-II is still run by the Marine Corps Systems Command in Quantico, VA, and is considered a subsidiary effort within the MRAP program generally.

Dec 18/07: BAE Systems Land & Armaments, LP Ground Systems Division in York, PA won a $645.4 million for firm-fixed-priced delivery order under a previously awarded contract (M67854-07-D-5025, #006) to purchase 600 survivability-enhanced RG-33L MRAP CAT-II vehicles, incorporating various engineering change proposals and delivering vehicle sustainment Integrated Logistics Support (ILS). John Swift, BAE Systems’ MRAP program manager, adds that:

“The enhanced version has markedly improved the RG33 and incorporates the most advanced suite of armor protection giving its crew a decided edge in combat survivability.”

Work will be performed at BAE facilities in York, PA; Aiken, SC; and Sealy, TX; with assistance from Spartan Motors Chassis’ facility in Charlotte, MI and Demmer Corporation’s facility in Lansing, MI. Deliveries are expected to begin in May 2008 and be completed by June 2008. This contract was competitively procured.

Dec 18/07: Armor Holdings’ Stewart & Stevenson Tactical Vehicle division in Sealy, TX, currently doing business as BAE-TVS, won $458.1 million for a firm-fixed-priced delivery order under a previously awarded contract (M67854-07-D-5030, #003). They will deliver 668 Caiman CAT II MRAP vehicles with the 4-passenger CAT I seating configuration, incorporating engineering change proposals for survivability enhancement and delivering sustainment parts and support. Work will be performed in Sealy, TX, and Fairfield, OH; deliveries will commence in May 2008 and are expected to be completed by July 2008. This contract was competitively procured.

As this accompanying DoD release notes, the Marine Corps issued a number of MRAP orders on this day. See also BAE Systems Dec 19/07 release.

Nov 8/07: The Stewart & Stevenson Tactical Vehicle Division of BAE Armor Holdings in Sealy, TX received a $50.2 million firm-fixed-priced delivery order #0002 under previously awarded contract (M67854-07-D-5030) for the purchase of Prescribed Load List (PLL) sustainment parts, Authorized Stockage List (ASL) sustainment parts, MRAP University Training, new equipment training and logistics demonstration support. Work will be performed in Sealy, TX and is expected to be complete October 2008.

Oct 30/07: A $36.3 million firm-fixed-priced modification under previously awarded contract (M67854-07-D-5025) for Integrated Logistics Support sustainment. Work will be performed in York, PA and is expected to be complete by January 2008.

Oct 18/07: $278.4 million for firm-fixed-price delivery order #0005 under previously awarded contract (M67854-07-D-5025) for another 399 Mine Resistant Ambush Protected Category II vehicles (RG-33L), and another 112 MRAP Category II Ambulance Variant (RG-33 MEDEVAC) vehicles. Work will be performed in York, PA and is expected to be complete by April 2008. This contract was competitively procured.

BAE also received a $44.3 million for firm-fixed-price delivery order #0004 under previously awarded contract ( M67854-07-D-5025) for the purchase of 89 MRAP vehicle Category I United States Special Operations Command Variants (RG-33 SOCOM), and vehicle sustainment Integrated Logistic Support. Work will be performed in York, PA and is expected to be complete by April 2008. This contract was competitively procured.

A Nov 6/06 BAE Systems release addressed these orders, adding that production will be performed at BAE Systems’ facilities, in York, PA; Aiken, SC; and Sealy, TX; Spartan Motors Chassis’ facility in Charlotte, MI; and Demmer Corporation’s facility in Lansing, MI. Deliveries are expected to be complete by March 2008 for the Category I RG-33 4×4 vehicles, and April 2008 for the Category II RG-33L/MEDEVAC vehicles.

Oct 9/07: BAE Systems and the Red River Army Depot (RRAD) signed a Memorandum of Intent for a partnership to support production of Mine Resistant Ambush Protected (MRAP) vehicles during the Association of the U.S. Army’s (AUSA 2007) Annual Symposium and Exhibition in Washington, DC.

The memorandum states that RRAD and BAE Systems have agreed to enter into a Public Private Partnership for MRAP production and follow-on support, similar to the existing M2/M3 Bradley public-private remanufacture program undertaken with RRAD. BAE notes that they are “contracted to build three of the five MRAP variants,” and imply that the agreement covers all of them – if so, General Dynamics’ orders would also be covered. Further specifics were not included in BAE’s Oct 31/07 release

July 16/07: The mystery of the missing Category II JERRV orders for BAE’s RG-33L appears to have been solved via a $21.9 million modification to previously awarded contract (M67854-07-D-5025) for Delivery Order #0003, which changes 239 MRAP orders from CAT I RG-33s to CAT II RG-33L vehicles. Work will be performed in York, PA, and is expected to be completed by July 2008. Contract funds will not expire at the end of the current fiscal year. The Marine Corps Systems Command, Quantico, VA issued the contract.

BAE has confirmed the exact breakdown to DID; the US SOCOM CAT I order remains stable, leaving them with a revised order of $235.8 million for:

• 16 RG-33 Category I MRUV patrol vehicles;
• 170 RG-33 Category I vehicles modified for US Special Operations Command, out of their total MRAP allotment of 333 vehicles;
• 239 RG-33L Category II JERRV squad/specialty EOD vehicles

• 16 RG-33L Category II Ambulance variants, the first vehicles in the competition listed specifically for the ambulance role. According to BAE, this version includes “a novel litter lift system. The vehicle also provides space for a medic work station and key medical equipment.”

As of this date, 62.7% of the MRAP program’s 7,774 vehicle orders have been issued. With this modification, BAE Systems’ share of orders to date rises to 34.9% (31 RG-33, 170 RG-33 SOCOM, 314 RG-33L, 16 RG-33L Ambulance = 531 vehicles + Armor Holdings 1,170 Caimans), vaulting them into a close second place behind Force Protection, Inc’s 36.5%. This modification doesn’t change the overall numbers, but does provide BAE Systems with more of a balanced MRAP vehicle portfolio.

July 13/07: BAE Systems’ new subsidiary Armor Holdings, Inc. received a $518.5 million firm-fixed-priced delivery order under a previously-awarded indefinite-delivery/indefinite-quantity contract (M67854-07-D-5030, #002) for the purchase of 1,154 MRAP Category I MRUV patrol vehicles, and 16 MRAP Category II JERRV squad/specialty vehicles.

According to Armor Holdings’ release, the vehicles will be the FMTV Truck based Caiman design they originally submitted to the competition – not more BAE vehicles. Work will be performed in Sealy, TX, and is expected to be complete in February 2008.

June 28/07: BAE Systems Land & Armaments Ground Systems Division in York, PA received $213.9 million for firm-fixed-priced delivery order #0003 under previously awarded contract (M67854-07-D-5025). Production will take place at BAE Systems’ York, PA and Aiken, SC facilities, and at “major partner facilities” (likely Armor Holdings) in Lansing, MI and Charlotte, MI; work is expected to be complete by July 2008.

Order #1 had been for test vehicles, while order #2 involved 15 RG-33s and 75 of the larger RG-33Ls with their robotic arm. This order was revised, and covers:

• 255 RG-33 Category I MRUV patrol vehicles;
• 170 RG-33 variants for US Special Operations Command, out of their total MRAP allotment of 333 vehicles;
• 16 RG-33L Category II Ambulance variants, the first vehicles in the competition listed specifically for the ambulance role. According to BAE, this version includes “a novel litter lift system. The vehicle also provides space for a medic work station and key medical equipment.”

At the time, DID wondered about the RG-33L’s absence, but that has since been remedied in spades. We said:

“The surprising absence here was the RG-33L, whose unique features appeared to make it a very strong contender for Explosive Ordnance Disposal roles, route-proving, and other classic Category II tasks. In one of the marked departures from normal procurement procedures that characterizes the urgent nature of the MRAP program, BAE’s new offering had generated enough initial interest to justify a 75 vehicle order at the very beginning of the competition, even before testing had begun.

The RG-33’s win in the SOCOM role is an especial vote of confidence, and offers a strong base to build on for BAE in conjunction with the RG-33L’s ambulance win. Nevertheless, the curious incident of the mainstream RG-33L orders remains one of the salient features of this contract.”

Like all of the MRAP orders, this contract includes sustainment and Integrated Logistics Support (ILS) of 90 days worth of spares, forward deployment blocks, maintenance workshop blocks, field service representatives, and operator and maintenance training. See also BAE Systems’ release.

April 3/07: An $8.2 million for firm-fixed-priced modification to existing delivery order #0002 under previously awarded contract (M67854-07-D-5025) for MRAP Low Rate Initial Production vehicle sustainment Integrated Logistic Support. Work will be performed in York, PA, and is expected to be complete by April 2008. All contract funds will expire at the end of the current fiscal year.

Due to the urgency of getting vehicles in theater, designs deemed low risk are being contracted for fielding even before testing is complete and a field support system exists. Hence the Feb 14/07 order for 75 RG-33Ls and 15 RG-33s. This contract provides that field support via the contractor, and will consist of 90 day consumables, forward deployment blocks, maintenance workshop blocks, field service representatives, operator and maintenance training, and contract data requirements lists.

Feb 14/07: BAE Systems Ground Systems Division in Santa Clara, CA receives a $55.4 million firm-fixed-price delivery order under previously awarded indefinite-delivery/ indefinite-quantity contract # M67854-07-D-5025 for 90 MRAP vehicles: 15 Category I, and 75 Category II. All will be built in York, PA.

DID has talked to the MRAP Program Office, who confirms that BAE will be delivering 75 of their new RG-33Ls as the Category II delivery order, and 15 RG-33s as the Category I delivery order.

Appendix A: MRAP Competition Half-Time Update, June 28/07

We are very close to the halfway mark. Of the envisaged 7,774 vehicles, 3,707 (46.7%) have now been ordered. Thus far, BAE Systems’ share is 14.3%, in 3rd place behind Force Protection (48%) and Navistar (32.8%).

The program will continue to issue new orders as production gets close to fulfilling existing contracts. In other words, once one’s vehicles are tested and approved, the race for MRAP share becomes a function of quality production rate. Key rival Force Protection recently stated that they plan to reach a production rate of 400 vehicles per month through their Force Dynamics joint venture by February 2008. BAE has augmented its own capabilities in the meantime, by acquiring MRAP rival Armor Holdings.

In order to finish strong in the MRAP competition and win significant share, BAE has its benchmark in front of it. Now it comes down to operational execution… and perhaps a solution to the mystery of the RG-33L’s weak performance thus far.

(Updated July 2007) The RG-33L mystery appears to have been solved. The use of an order shift to redistribute RG-33 production to RG-33Ls within the July 16/07 order, however, rather than just ordering additional vehicles, suggests production capacity limits for BAE that are surpassed by its rivals. With MRAP shaping up as a production race, this could become a competitive issue for its high-end vehicle set.

Additional Readings

• BAE Systems – Wheeled Vehicles Electronic Information Kit

• Defense News (Oct 1/07) – MRAP II Deadline Passes. Notes some of the other competitors, but doesn’t mention BAE.