BAE Systems Ordnance Systems, Inc. v. Fluor Federal Solutions, LLC

CourtDistrict Court, W.D. Virginia
DecidedSeptember 17, 2025
Docket7:20-cv-00587
StatusUnknown

This text of BAE Systems Ordnance Systems, Inc. v. Fluor Federal Solutions, LLC (BAE Systems Ordnance Systems, Inc. v. Fluor Federal Solutions, LLC) is published on Counsel Stack Legal Research, covering District Court, W.D. Virginia primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
BAE Systems Ordnance Systems, Inc. v. Fluor Federal Solutions, LLC, (W.D. Va. 2025).

Opinion

AT ROANOKE, VA FILED September, 17, 2025 IN THE UNITED STATES DISTRICT COURT LAURA A. AUSTIN, CLERK FOR THE WESTERN DISTRICT OF VIRGINIA BY-s/ KELLY BROWN ROANOKE DIVISION DEPUTY CLERK BAE SYSTEMS ORDNANCE ) SYSTEMS, INC., ) ) ) Civil Action No. 7:20-cv-587 Plaintiff/ Counterclaim Defendant, ) ) By: Hon. Robert S. Ballou V. ) United States District Judge ) FLUOR FEDERAL SOLUTIONS, LLC, ) ) ) Defendant/ Counterclaim Plaintiff. )

MEMORANDUM OPINION OF FINDINGS OF FACT AND CONCLUSIONS OF LAW The Army maintains a nitrocellulose facility operated by BAE in Radford, Virginia. BAE contracted with the Army to design and build a new production plant and subcontracted that work with Fluor Federal Solutions in a firm-fixed-priced contract with a total cost of $245,690,422.00. Design delays, construction delays and scope and cost changes plagued the project from the start. Eventually, the project reached its substantial completion many years behind the original completion date and millions of dollars over the original contract price. This lawsuit explored the reasons for those delays and cost increases over the course of a three-week trial, and like so many things, the fault lies with both BAE and Fluor. BAE seeks damages in excess of $19,000,000 for delays to the completion of the project, the abnormal maintenance costs to previous facility beyond the completion date, and consequential damages paid to the Army because of delay to the completion and operation of the new facility. Fluor’s five-count counterclaim seeks $179,181,683 in damages because of the deficiencies in the design

it inherited from BAE’s previous contractor, changes to the scope of work, delays caused by BAE and cost increases it claims were the fault of BAE or beyond its control. At the heart of the dispute lies a firm-fixed-priced contract which allocated the risks of construction delays and cost increases. Fluor cannot recover for increased costs caused by its

oversights or mistakes in completing the work. Nor can it delay the completion of the project to account for design delays. But a firm-fixed-priced contract does not give BAE carte blanche to change the scope of the work without providing an equitable adjustment to the costs or schedule. Nor can it shirk responsibility for delays to the schedule it causes. My findings of fact and conclusions of law from the trial follow in narrative form. I. FACTUAL BACKGROUND1 BAE manages an ammunition plant for the United States Army in Radford, Virginia commonly known as the Radford Arsenal. In January 2012, the Army awarded BAE a contract to design and build a new nitrocellulose production facility at the Arsenal, which would include (1) a cutter warehouse; (2) an acid tank farm; (3) a nitration building; (4) a stabilization building;

(5) a dewater and packout building; and (6) an administrative and laboratory building. The contract required BAE to construct the Facility around the BOWAS process, a proprietary method for manufacturing nitrocellulose. A. Pre-Contracting Period In February 2012, BAE entered into two subcontracts with Lauren Engineers and Constructors, Inc. The first contract was for the design of the Facility, and the second contract

1 Some exhibits and a limited portion of the testimony at trial referred to “Highly Sensitive Documents” (“HSDs”). Resolution of the parties’ claims has required the court to refer to HSDs, but the court has ensured that none of the information subject to such protection is included in this opinion. Thus, the entirety of this opinion will be placed on the public docket. provided for the construction of the Facility. BAE and Lauren’s relationship soured in the following years because of delays and cost overruns and by 2014, BAE concluded that its contract with the Army did not cover the expected cost or provide sufficient time to complete the facility. BAE sought to “rebaseline” its contract with the Army and solicited a proposal for a

“firm fixed-price contract” from Lauren to complete the entire project. A firm-fixed-price contract provides for a definite price to complete the desired work and is not subject to adjustment based on the contractor’s cost in performing the contract. The contractor accepts maximum risk and full responsibility for all costs and resulting profit or loss under a firm-fixed- price contract. Federal Acquisition Regulation 16.202-1. Rebaselining to a firm-fixed-priced contract with Lauren would allow BAE to give the Army an accurate estimate for the total cost of the Facility. In turn, the Army could obtain adequate funding for the project. BAE negotiated with Lauren throughout 2014 to arrive at a firm-fixed-price contract, but the parties were unable to reach agreement. On January 23, 2015, BAE ordered Lauren to stop working on the design of the Facility.

By March 10, 2015, BAE terminated both Lauren subcontracts for convenience. BAE requested that Lauren provide it with copies of all “drawings and specifications which have been released for construction” and all “‘as is’ drawings in an unprotected native, editable, electronic machine- readable file format.” On April 6, 2015, BAE released Lauren for its work on the project. The release between Lauren and BAE terminating the Lauren contracts contained the following acknowledgement regarding the drawings: [T]he partially completed drawings and designs prepared by [Lauren] . . . are not final documents and are not intended to be relied on as ‘Issued for Construction’ documents. [BAE] uses these documents at [BAE]’s sole risk and without liability or legal exposure to [Lauren].

Shortly thereafter, BAE collected Lauren’s design documents and retained two engineering contractors, Power Engineers and Jacobs Solutions, to “validate” the Lauren design. By terminating Lauren as the designer and builder of the new facility, BAE had no contractor to fulfill its contractual obligation to the Army to build a new nitrocellulose plant. So, it immediately began the process to find a new design/builder for the new Facility. On April 16,

2015, the company hosted interested potential bidders - AECOM, HiTT, Jacobs Engineering, Burns and McDonnell (“Burns”) and Defendant Fluor Federal Solutions, LLC for an “Industry Day,” where BAE provided the attendees information about the project and the bidding process to allow them to analyze and assess the scope and nature of the project before submitting bids. BAE told the Industry Day attendees that it had “obtained native design format design files from [Lauren] that provide an estimated 85% design solution with some areas requiring additional engineering. . .” The areas requiring additional engineering were listed: “Administration building (laboratory, layout),” “Packout Process,” “Waste water recover process,” “Tepid water system (safety showers/eyewash),” “Metal removal system,” “Fume Abatement (use existing SCR or new system),” “HVAC,” “Fire protection,” and “Pre-PHA for the main operations is complete.

Final HAZOPs for Fume Abatement, Cellulose Handling, and Packout remain.” BAE also advised potential bidders that the required design work for the project included “[v]alidation of the existing design (estimated at 85%)” and “[c]ompletion of design and validation of mechanical performance.” Following Industry Day, BAE provided interested bidders with the Lauren design documents to use in the development of their bids. BAE uploaded the design documents to a SharePoint site in several batches between June and September 2015. Bidders were told that the documents were based on work in progress as of January 28, 2015 when Lauren put “pens down.” BAE regularly updated the Lauren documents shared with Industry Day participants with redlines and corrections.

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BAE Systems Ordnance Systems, Inc. v. Fluor Federal Solutions, LLC, Counsel Stack Legal Research, https://law.counselstack.com/opinion/bae-systems-ordnance-systems-inc-v-fluor-federal-solutions-llc-vawd-2025.