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UNITED STATES SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
Form 10-K
     
þ
  ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934
 
    For the Fiscal Year Ended December 31, 2004
 
o
  TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934
 
    For the transition period from           to
Commission file number: 001-15423
Grant Prideco, Inc.
(Exact name of registrant as specified in its charter)
     
Delaware
(State or Other Jurisdiction
of Incorporation or Organization)
  76-0312499
(I.R.S. Employer
Identification No.)
 
400 N. Sam Houston Pkwy. East
Suite 900
Houston, Texas
(Address of Principal Executive Offices)
  77060
(Zip Code)
(281) 878-8000
(Registrant’s telephone number, including area code)
Securities to be registered pursuant to Section 12(b) of the Act:
     
Title of Each Class   Name of Each Exchange On Which Registered
     
Common Stock, par value $0.01 per share   New York Stock Exchange
Securities registered pursuant to Section 12(g) of the Act:
None
      Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days.     Yes þ          No o
      Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of registrant’s knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K.     o
      Indicate by check mark whether the registrant is an accelerated filer (as defined in Exchange Act Rule 12b-2).     Yes þ          No o
      Aggregate market value of the voting and non-voting common equity held by nonaffiliates of the registrant: $1,450,165,174. This figure is estimated as of June 30, 2004, at which date the closing price of the registrant’s shares on the New York Stock Exchange was $18.46 per share.
      Number of shares of Common Stock outstanding as of March 18, 2005: 124,636,659
DOCUMENTS INCORPORATED BY REFERENCE
      Listed below is the document parts of which are incorporated herein by reference and the part of this report into which the document is incorporated:
      (1) Proxy Statement for 2005 Annual Meeting of Stockholders — Part III
 
 


TABLE OF CONTENTS
             
        Page
         
 PART I
   Business     2  
     General     2  
     Drilling Products and Services Segment     2  
     Drill Bits Segment     4  
     Tubular Technology and Services Segment     6  
     Other Segment     8  
     Other Business Data     8  
   Properties     10  
   Legal Proceedings     11  
   Submission of Maters to a Vote of Security Holders     11  
 PART II
   Market For Registrant’s Common Equity, Related Stockholder Matters, and Issuer Purchases of Equity Securities     11  
   Selected Financial Data     12  
   Management’s Discussion and Analysis of Financial Condition and Results of Operations     13  
     General     13  
     Market Trends and Outlook     13  
     Future Market Trends and Expectations     14  
     Results of Operations     15  
     Liquidity and Capital Resources     19  
     Related-Party Transactions     23  
     Off-Balance Sheet Financing     23  
     Recent Accounting Pronouncements     24  
     Critical Accounting Policies and Estimates     25  
     Forward-Looking Statements and Exposures     27  
   Quantitative and Qualitative Disclosures About Market Risk     32  
   Financial Statements and Supplementary Data     33  
   Changes in and Disagreements with Accountants on Accounting and Financial Disclosure     88  
   Controls and Procedures     88  
 PART III
   Directors and Executive Officers of the Registrant     92  
   Executive Compensation     92  
   Security Ownership of Certain Beneficial Owners and Management and Related Stockholder Matters     92  
   Certain Relationships and Related Transactions     92  
   Principle Accounting Fees and Services     92  
 PART IV
   Exhibits and Financial Statement Schedules     92  
    Schedule II — Valuation and Qualifying Accounts     96  
     Signatures     97  
 Form of Executive Restricted-Stock Agreement
 Form of Executive Restricted-Stock Agreement
 Form of Executive Stock Option Agreement
 Form of Executive Stock Option Agreement
 Amendment 1 to Supplier Agreement
 Amendment 2 to Supplier Agreement
 Consent of Ernst & Young LLP
 Certification of Michael McShane
 Certification of Matthew D. Fitzgerald
 Certification Pursuant to Section 906

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FORM 10-K
PART I
Item 1. Business
General
      We are the world leader in drill stem technology development and drill pipe manufacturing, sales and service; a global leader in drill bit technology, manufacturing, sales and service; and a leading provider of high-performance engineered connections and premium tubular products and services. Our drill stem and drill bit products are used to drill oil and gas wells while our tubular technology and services are primarily used in drilling and completing oil and gas wells. Our customers include drilling contractors; North American oil country tubular goods (OCTG) distributors; major, independent and state-owned oil companies; and other oilfield service companies. We primarily operate through three business segments: (1) Drilling Products and Services, (2) Drill Bits and (3) Tubular Technology and Services. In the first quarter of 2004, we announced an organizational restructuring that resulted in our former Marine Products and Services businesses now being reflected in the Tubular Technology and Services segment. Prior periods have been restated for comparability.
      Our business is primarily dependent on the level of oil and gas drilling activity worldwide, which, in turn, depends on the level of capital spending by major, independent and state-owned exploration and production companies. This capital spending is driven by current prices for oil and gas and the perceived stability and sustainability of those prices. All of our business segments generally track the level of domestic and international drilling activity, however, their revenues, cash flows and profitability follow the rig count at different stages within the market cycles. Drill pipe demand is also a function of customer inventory levels and typically lags changes in the worldwide rig count. In a declining market, customers are contractually required to purchase ordered drill pipe even if they will no longer need that pipe. This creates a situation where our customers have an inventory of excess drill pipe. Consequently, in a market with increasing activity, customers delay purchasing until they no longer have sufficient inventory to sustain current and near-term expected future activity. Drill bit demand and this segment’s earnings and cash flows have closely tracked the worldwide rig count. Within our Tubular Technology and Services segment, there are four product lines: Atlas Bradford premium connections, Tube-Alloy accessories, TCA premium casing and XL Systems large bore connections and services. Results for this segment’s Atlas Bradford, Tube-Alloy and TCA product lines predominantly follow changes in North American (in particular Gulf of Mexico) offshore drilling, deep drilling and natural gas drilling rig counts, but short-term demand for Atlas Bradford products also can be affected by inventories at OCTG distributors. The TCA product line also is affected by the level of U.S. OCTG mill activity. This segment’s XL Systems product line generally follows the level of worldwide offshore drilling activity.
      Additional information regarding our revenues and foreign investments by geographic region can be found in the footnotes to our consolidated financial statements starting on page 33 of this Annual Report on Form 10-K.
      Grant Prideco was incorporated in Delaware on June 22, 1990. Our corporate headquarters is located at 400 N. Sam Houston Pkwy. East, Suite 900, Houston, Texas 77060.
Drilling Products and Services Segment
      Our Drilling Products and Services segment manufactures and sells a variety of drill stem products used for the drilling of oil and gas wells. The principal products sold by this segment are: (1) drill pipe products, including tool joints, (2) drill collars and heavyweight drill pipe and (3) drill stem accessories.
      Our drill stem products wear out through a combination of friction and metal fatigue and generally are utilized by our customers for a three to five year period assuming regular use. Demand for our drill stem products is impacted primarily by changes in drilling activity and worldwide rig activity. However, since drill stem products are not consumables and represent a capital investment by our customers, demand for these products also is significantly impacted by the level of inventory held by our customers and their perceptions as to future activity and their near-term need for new drill stem products. As a result, even in periods of rising or

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strong drilling activity, our customers may elect to defer purchases until their own inventory reaches levels at which additional purchases are necessary to sustain their existing drilling activities.
      With the increased complexity of drilling activity, demand for our proprietary line of eXtremetm drilling and other premium drilling products has remained strong. This value-added product line coupled with our XT® (eXtreme torque) connections is specifically designed for extreme drilling conditions such as extended reach, directional, horizontal, deep gas, offshore and ultra-deepwater drilling, as well as high-temperature, high-pressure and corrosive well conditions. Operators and drilling contractors have embraced this product line as a way to improve their efficiency and assure performance when drilling under extreme conditions. We believe that our eXtreme product line offers some of the highest-performance drilling products ever brought to market and provides our customers with engineered solutions for some of their most challenging drilling applications. In addition to our eXtreme product line, our premium drill pipe products can also include our CT-M57tm connections that can withstand external pressures exceeding 25,000 psi and internal pressures nearing 30,000 psi, along with proprietary sour-service grades and other proprietary products.
      Our drill stem products are sold to a variety of customers, including oil and gas drilling contractors, rental tool companies and major, independent and state-owned oil and gas companies. Our customers’ purchasing decisions are generally based on operational requirements, quality, price and delivery. The principal competitors for our drill stem products include Drilco Group (a subsidiary of Smith International Inc.), Texas Steel Conversion, OMSCO Industries (a subsidiary of ShawCor Ltd.), IDPA and various smaller local manufacturers in the U.S. and in foreign countries. We typically compete on quality, technology, price and delivery and we believe we are the technological leader in our industry.
      The following is a description of our principal drill stem products:
Drill Pipe Products
      Drill pipe is the principal tool, other than the rig, required for the drilling of an oil or gas well. Its primary purpose is to connect the above-surface drilling rig to the drill bit. A drilling rig will typically have an inventory of 10,000 to 25,000 feet of drill pipe depending on the size and service requirements of the rig. Joints of drill pipe are connected to each other with a welded-on tool joint to form what is commonly referred to as the drill string or drill stem.
      When a drilling rig is operating, motors mounted on the rig rotate the drill pipe and drill bit. In addition to connecting the drilling rig to the drill bit, drill pipe provides a mechanism to steer the drill bit and serves as a conduit for drilling fluids and cuttings. Drill pipe is a capital good that can be used for the drilling of multiple wells. Once a well is completed, the drill pipe may be used again in drilling another well until the drill pipe becomes damaged or wears out.
      In recent years, the depth and complexity of the wells our customers drill, as well as the specifications and requirements of the drill pipe they purchase, have substantially increased. We estimate that over 95% of the drill pipe we sell outside of China is required to meet specifications exceeding minimum American Petroleum Institute (API) standards. We offer a broad line of premium drilling products designed for the offshore, international and domestic drilling markets. Our premium drilling products include our proprietary lines of XT connections and 57/8-inch drill pipe that delivers hydraulic performance superior to standard 51/2-inch drill pipe and weight benefits superior to standard 65/8-inch drill pipe.
Drill Collars
      Drill collars are used in the drilling process to place weight on the drill bit for better control and penetration. Drill collars are located directly above the drill bit and are manufactured from a solid steel bar to provide necessary weight.

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Heavyweight Drill Pipe and Other Drill Stem Products
      Heavyweight drill pipe is a thick-walled seamless tubular product that is less rigid than a drill collar. Heavyweight drill pipe provides a gradual transition zone between the heavier drill collar and the lighter drill pipe.
      We also provide kellys, subs, pup joints (short and odd-sized tubular products) and other drill stem accessories. These products all perform special functions within the drill string as part of the drilling process.
IntelliServtm Joint Venture
      We own 50% of this joint venture partially sponsored by the U.S. Department of Energy to commercialize intelligent drill pipe that permits real-time transfer of data through the drill string. This modified drill pipe is embedded with a telemetry system that permits two-way data transmission along the drill string at rates of up to two million bits per second, which is exponentially greater than the data transmission rates for measurement in the drilling and logging systems utilized today. We currently are in the field trial testing and refinement stage and have not yet introduced a product commercially. Due to the unproven nature of the technology and that it is still in its development state, we can provide no assurances that it will be successful or be able to be marketed and sold on a commercial basis.
Operations
      Our major drill stem manufacturing plants are located in the U.S., China, Italy, Mexico, Singapore and Indonesia. These products are sold and serviced through over 16 sales and service facilities located around the world. During the fourth quarter of 2003, we completed an evaluation of our existing manufacturing capacities and locations. Following this manufacturing rationalization study, we determined that we had excess capacity and duplicate operations in certain locations that could be eliminated without affecting our ability to quickly and efficiently react to market increases. As a result, we shut down our Bryan, Texas facility, significantly downsized our Canadian operations and rationalized certain operations in our Veracruz, Mexico and Navasota, Texas locations.
      We believe we are the only fully vertically integrated drill pipe manufacturer in the world, controlling each facet of the drill pipe manufacturing process. We manufacture (through a 50.01% owned joint venture) the green tube (drill pipe tube that has not been heat-treated or processed), the tool joint and complete the finishing and welding operations. We believe this unique manufacturing strategy provides us with significant competitive advantages over other drill pipe manufacturers, including those located outside the U.S. that may have labor and other cost advantages over our U.S.-based manufacturing operations. By controlling each facet of the drill pipe manufacturing process, we are able to tailor our processes and techniques to meet our customers’ demanding product specifications, particularly with respect to green drill pipe tubes with body wall thickness, wall uniformity and other features that exceed minimum API standards and are not readily available from third-party mills.
Drill Bits Segment
      Our Drill Bits segment’s products and services are comprised of the operations of ReedHycalog. This segment is a leading global designer, manufacturer and distributor of drill bits and related technology to the oil and gas industry. This segment also services its customer base through a technical sales and marketing network in virtually every significant oil and gas-producing region in the world. Drill bits are generally sold directly to oil and gas operators and, to a lesser extent, drilling contractors on turnkey and footage contracts. Competition is based on technical performance, price and service.
      The drill bit market consists of two product types: fixed-cutter bits and roller-cone bits. We manufacture and sell both product types on a global basis.
      Drilling through subsurface strata to locate oil and gas requires a drill bit to be run on drill pipe or conveyed through coiled tubing and rotated by surface rig equipment or downhole motors and turbines. Selecting the optimal bit for a particular application represents one of the many challenges faced by oil and

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gas companies and drilling contractors in planning a well. Similar to the drill stem market, the primary market driver is worldwide drilling activity or, more specifically, total footage drilled. In addition, demand is a function of well depth and complexity with demand for fixed-cutter bits tied more strongly to offshore, directional or horizontal drilling.
      Drill bits constitute a very small percentage of total well costs, but are a critical component of well-construction economics. The time required to drill a well is directly related to a drill bit’s rate of penetration and footage drilled prior to becoming dull and requiring replacement. On a cost-per-foot basis, selecting the appropriate drill bit significantly reduces drilling costs by decreasing drilling time and the number of trips required in and out of a well. Typically, roller-cone bits are most appropriate for shallow land rig operations, while higher performance roller-cone or fixed-cutter bits with better rates of penetration and longer lives offer the most economic choice for offshore and deep wells where rig rates and trip costs are high. However, there is a trend towards increased use of fixed-cutter bits in operations that traditionally have utilized roller-cone bits.
      We provide a complete series of drill bits incorporating advanced materials technology and a range of performance-enhancing features. This broad product offering provides customers with maximum flexibility in selecting drill bits. In addition, we provide drill bit selection and well-planning services through our field sales organization and bit optimization engineers.
      Our principal competitors for the sale of drill bits are Hughes Christensen (a division of Baker Hughes Inc.), Smith Bits (a division of Smith International Inc.), and Security DBS (a division of Halliburton Company) as well as numerous smaller competitors throughout the world.
Fixed-Cutter Bits
      ReedHycalog first manufactured fixed-cutter natural diamond bits in 1953 and synthetic polycrystalline diamond compact (PDC) bits in 1974.
      The predominant fixed-cutter bit used in the oil and gas industry is the PDC bit. PDC bits have no moving parts and are therefore intrinsically more reliable than roller-cone bits, but they are generally more sensitive to geological changes. PDC bits drill with a shearing action to remove rock by dragging the diamond elements through the formation as the drill bit body rotates. PDC bits allow faster rates of drilling penetration and can drill complete well sections without the need for bit replacement. As a result, they are used in high cost drilling locations (such as offshore or in remote locations) where their technical advantages reduce drilling time sufficiently to justify the higher cost product.
      We provide fixed-cutter bit types and technology under various brand names including TReXtm, SteeringWheeltm, Rotary Steerable and many others. One of the most significant innovations is our TReX cutter technology, which significantly increases abrasion resistance (wear life) without sacrificing impact resistance (toughness). This technology produces material that maintains a sharp, low-wearing cutting edge that is producing results that exceed conventional standards for PDC bit performance.
      During 2004, this segment acquired the assets of Novatek International, Inc. (Novatek), a manufacturer of PDC cutters, as well as Diamond Products International, Inc., a leading provider of bi-center bits.
Roller-Cone Bits
      ReedHycalog has manufactured roller-cone bits since 1916 and produces roller-cone bits for a wide variety of oil and gas drilling applications. Roller-cone bits consist of three rotating cones that have cutting teeth, which penetrate the formation through a crushing action as the cones rotate in conjunction with the rotation of the drill pipe. This cutting mechanism, while less efficient than fixed-cutter bits, is more versatile in harder formations, or where the geology is changing. We manufacture roller-cone drill bits with milled teeth and with tungsten carbide insert teeth, which have a longer life in harder formations.
      We market our roller-cone products and technology globally under various brand names including TuffDutytm, Titantm and TuffCuttertm.

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Operations
      We manufacture fixed-cutter bits in Stonehouse (U.K.) and in Houston, Texas and roller-cone bits in Singapore and a separate facility in Houston, Texas. In January 2005, in connection with an expansion of our Singapore operations, a significant portion of the production of roller-cone bits has been moved from Houston, Texas to Singapore. All facilities are ISO 9001 and 14001 certified.
      We market our drill bits through a global sales and marketing network with our employees strategically positioned around the world. Sales people are located in North and South America, Europe, CIS, Africa, Middle East and Asia. The sales force is technologically sophisticated and has developed strong regional expertise.
Tubular Technology and Services Segment
      Our Tubular Technology and Services segment provides a full range of premium threaded connections for casing, production tubing and other accessory equipment. This segment also manufactures and sells premium casing for use with third-party connections and is a leading supplier of tubulars and threaded connections for the large-bore tubular market. During 2003, we made a strategic decision to exit the manufacture and sale of premium tubing. Additionally, in 2004 we sold our Texas Arai couplings business which is now reflected as discontinued operations in our accompanying financial statements.
      Although we sell our large-bore tubulars and connections on a world wide basis, the demand for the majority of our tubular technology and services is heavily dependent upon North American natural gas drilling activity, and it is more particularly dependent upon rigs drilling for deep gas in the Gulf of Mexico. On a short-term basis, demand for many of these products is also affected by the level of inventory held by distributors of OCTG. Distributors often reduce purchases until their inventory positions are brought in line with then-prevailing market conditions.
      Over the long-term, a key factor positively impacting demand for our tubular technology and services is the U.S. dependence on natural gas as a fuel. Gas wells generally encounter higher reservoir pressure and corrosive environments, which both typically increase proportionally with increased depths. Therefore, gas wells can require larger-diameter tubulars with thicker walls, higher strength steel grades and special metallurgy that is resistant to corrosive elements. For these wells, premium connections, as opposed to standardized API connections, are typically used to ensure the integrity of the tubulars throughout the life of the well. Also, depletion rates for natural gas wells in the U.S. have significantly increased during the past decade, which indicates that more wells will need to be drilled to keep production levels constant. This increased demand in North America for natural gas should increase the number of natural gas wells being drilled and completed, thus increasing demand for our tubular technology and services.
      The following is a description of our principal premium connections and tubular products and services:
Atlas Bradford® Threading and Service
      We market our premium engineered connections primarily through our Atlas Bradford product line, which has been recognized as one of the industry’s leading connections for more than 40 years. We offer this product line primarily in the U.S. and Canada due to a licensing arrangement that we previously entered into in which the international rights to our Atlas Bradford connection line were licensed to a third party. We also manufacture and sell connections for drilling with casing and expandable operations on a worldwide basis and recently introduced our licensed ATS-Etm semi-premium connection for sale on a worldwide basis.
      Our customers use premium connections when they need a connection that maintains a gas-tight seal while subjected to extreme tension, pressure and compression forces or while drilling near environmentally sensitive areas. The failure of a premium connection can be a catastrophic event, leading to the loss of a well or a blowout.
      We actively promote our premium connections to oil and gas operators, the ultimate end-users of the products, while selling the premium connections through a network of major distributors in the U.S. and

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Canada. Additionally, we provide tubular (casing, liner and tubing) string design recommendations, a full range test and demonstration facility, plus field service personnel to assist in the running of the products. Our principal competitors for premium connections are Hydril Company, Vallourec and Mannesmann Tubes, the Tenaris Group, Sumitomo, Kawasaki Steel, Lone Star Steel, Citra Tubindo, Hunting Interlock, Inc., Benoit, Inc. and numerous other competitors domestically and internationally.
Tube-Alloytm Accessories
      Tubular accessories are manufactured and sold through our Tube-Alloy product line and include flow control equipment, such as vacuum-insulated tubing, pup joints and landing nipples. Our vacuum-insulated tubing represents an advanced flow-control solution used to minimize paraffin deposits, gas hydrate formation and annular pressure buildup in deepwater production environments. Through our Tube-Alloy product line, we thread third-party tubular products with our Atlas Bradford connections as well as with third-party connections licensed to us. Our competitors for these products and services include Hunting Interlock, Inc., Benoit, Inc., Oil Tools International, international steel mills and numerous other regional competitors in the U.S. and worldwide.
TCAtm
      Premium casing products are offered through our TCA product line. These product offerings are designed to address that segment of the oilfield tubular casing market that requires special product characteristics and performance not generally offered by the tubular steel mills. Our TCA product line also provides tubular processing services for major tubular steel mills.
      We manufacture and sell premium casing, which includes high-performance, proprietary and custom-designed OCTG from 5 to 17 inches in diameter as well as API casing. Our premium casing is designed for critical applications. To capitalize on the high value spot market, we maintain common and high-alloy green tube inventories to provide quick delivery of custom-finished casing and coupling stock. To meet exact customer specifications and delivery requirements, we offer our specialized Premium Pipe Paktm product line. Premium Pipe Pak is an innovative bundling of proprietary casing, premium engineered connections and inspection services offered in conjunction with an independent third-party inspection company. This product line allows the customer the option of having threaded and inspected critical-service casing shipped “rig-ready” directly to the customer’s well site, which reduces costs and delivery times.
XL Systems
      Our XL System’s product line offers the customer an integrated package of large-bore tubular products and services for offshore wells. This product line includes our proprietary line of wedge thread marine connections on large-bore tubulars and related engineering and design services. We provide this product line for drive pipe, jet strings and conductor casing. We also offer weld-on connections and service personnel in connection with the installation of these products. We also completed development of our new high strength Vipertm weld-on connector that we believe will permit us to penetrate traditional markets that do not require the enhanced performance of our proprietary wedge thread design.
      Risers range from 95/8-inches to 133/8-inches and represent that section of the offshore production system from the wellhead and mudline up to the offshore production platform, which is typically either a floating platform, tension leg platform or SPAR. We currently offer top tension production risers and have begun to bundle our riser products with other third-party technology to offer a complete line of riser products. Our risers are sold with our various marine riser connectors. The tubular and coupling components of our riser products are often manufactured for our XL Systems product line by our Atlas Bradford and TCA product lines.
      Our XL Systems product line competes with DrilQuip, Vetco, Oil States, Franks and various other competitors domestically and internationally.

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Operations
      Our Tubular Technology and Services segment operations are located in Texas, Louisiana, Oklahoma, Wyoming, Vlissingen, The Netherlands and Canada. We also offer accessory threading services in Venezuela. In connection with our TCA operations in Muskogee, Oklahoma, we have entered into a long-term supply agreement with U.S. Steel Corporation that we expect will supply the majority of our steel needs at this location for the next several years. In addition, during the latter part of 2003, we moved our XL Systems Asia Pacific facility from Singapore to a new manufacturing location in Batam Island, Indonesia.
Other Segment
      Our Other segment included our industrial drill pipe operations and our construction casing and water well operations. We exited the industrial drill pipe business in the second quarter of 2003 and the construction casing and water well business with the sale of Star Iron Works (Star) in the first quarter of 2003. As of the end 2004, the remaining inventory related to the industrial drill pipe operations had been sold.
      In 2003, we moved our joint ventures relating to POS-GRIP technology from our Tubular Technology and Services segment to our Other segment. Prior periods have been restated to reflect this change. During the first quarter of 2004, we sold to our partner our rights to the POS-GRIP technology for jack-up exploration applications and have granted our partner an option to purchase our rights to POS-GRIP technology for subsea applications.
Other Business Data
Research and Engineering
      We maintain an active research and engineering program. The program improves existing products and processes, develops new products and processes, and improves engineering standards and practices that serve the changing needs of our customers. Our expenditures for research and engineering activities totaled $20.5 million, $17.7 million and $3.2 million in 2004, 2003 and 2002, respectively. These costs do not include amounts expended by our IntelliServ joint venture, which is accounted for as an equity-method investment. The significant increase from 2002 to 2003 related primarily to the ReedHycalog acquisition, which has an extensive research and engineering program.
Patents
      Many of our business lines rely on patents and proprietary technologies. We currently have numerous patents issued or pending. Many of our patents provide us with competitive advantages in our markets. Although we consider our patents and our patent protection to be important for our existing business and for the development of new technologies and businesses, we do not believe that the loss of one or more of our patents would have a material adverse effect on our business as a whole.
Backlog
      As of December 31, 2004, we had a product backlog of $270.5 million, representing 29% of our total revenues for the year ended December 31, 2004, which we expect to complete during 2005. This backlog was comprised of $203.3 million from Drilling Products and Services and $67.2 million from Tubular Technology and Services. We had a product backlog as of December 31, 2003 and 2002, of $120.6 million and $87.2 million, respectively. These year-end backlogs represented 15% and 14% of our total revenues for those years, respectively. The increase in product backlog from 2003 to 2004 reflects the strengthening of overall market conditions for oil and gas drilling.
Insurance
      We believe that we maintain insurance coverage that is adequate for the risks involved. However, there is always a risk that our insurance may not be sufficient to cover any particular loss or that our insurance may not cover all losses. For example, while we maintain product liability insurance, this type of insurance is limited in

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coverage, and it is possible that an adverse claim could arise that exceeds our coverage. Further, insurance rates are subject to wide fluctuations, and changes in coverage could result in increases in our cost or higher deductibles and retentions.
      We do not maintain political risk insurance (generally designed to cover expropriation and nationalization exposures), but do maintain all-risk property insurance that covers losses from insurrection, civil commotion and uprising. This insurance does not cover losses resulting from a declared state of war and provides a limited range of coverage from terrorist attacks.
Federal Regulation and Environmental Matters
      Our operations are subject to federal, state, local and foreign laws and regulations relating to the energy industry in general and the environment in particular. Environmental laws have over the years become more stringent, and compliance with such laws increases our overall cost of operations. In addition to affecting our ongoing operations, applicable environmental laws can require us to remediate contamination at our properties, at properties formerly owned or operated by us, and at facilities to which we sent waste materials for treatment or disposal and impose liability for related damages of natural resources. While we are not currently aware of any situation involving an environmental claim that would likely have a material adverse effect on our business, it is always possible that an environmental claim could arise with respect to one or more of our current businesses or a business or property that one of our predecessors owned or used that could have a material adverse effect.
      Our expenditures to comply with environmental laws and regulations were not material in 2004, and are not expected to be material in 2005. We also believe that we are in material compliance with applicable environmental requirements and our costs for compliance with environmental laws and regulations are generally within the same range as those of our competitors. However, we can offer no assurance that our costs to comply with environmental laws will not be material in the future. Prior to our acquisition, ReedHycalog was conducting remediation of groundwater at certain of its facilities. Based on currently available information, the indemnification provided by Schlumberger in the acquisition agreement and contractual indemnities from other third parties, we do not believe that these matters will result in any material effect on the Company’s capital expenditures, earnings or competitive position. However, there can be no guarantee that the indemnities will be available to cover all costs or that material expenditures will not be incurred.
      Our operations are also affected by trade laws affecting the import of OCTG, drill pipe and other products into the U.S. Although the majority of our manufacturing operations, including the capital investment, employees and costs and expenses associated therewith, are located in the U.S., we have key manufacturing facilities located outside the U.S., including our drill bit operations in the U.K. and Singapore, our 50.01% owned Voest-Alpine Tubulars GmbH & Co KG (Voest-Alpine) subsidiary located in Austria and our tool joint manufacturing operations in Mexico and Italy, that support our domestic operations. Our premium tubular business also is affected by the level of foreign imports of tubular products into the U.S.
      Imports of products from our foreign locations that are utilized by our domestic manufacturing operations can be the subject of investigations, including antidumping and countervailing duty orders, into whether such products are unfairly priced at low levels (i.e., dumping) and causing material damage to the domestic industry, as well as investigations under Section 201 of the trade laws into whether such imports have seriously damaged the domestic industry. Although we believe we are the clear price leader for drill pipe and other drill stem products and do not utilize imports from our foreign facilities to “dump” our products, our products have been, and may in the future be, the subject of such investigations.
Employees
      As of February 28, 2005, we had 4,064 employees. Certain of our operations are subject to union contracts. These contracts, however, cover approximately 9% of our total employees. We believe our relationship with our employees is good.

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Available Information
      We file annual, quarterly, and other reports and other information with the Securities and Exchange Commission (SEC) under the Securities Exchange Act of 1934 (the “Exchange Act”). You may read and copy any materials that we file with the SEC at the SEC’s Public Reference Room at 450 Fifth Street, NW, Washington, DC 20549. You may obtain additional information about the Public Reference Room by calling the SEC at 1-800-SEC-0330. In addition, the SEC maintains an Internet site (http://www.sec.gov) that contains reports, proxy information statements, and other information regarding issuers that file electronically with the SEC, including us.
      We also make available free of charge on or through our Internet site (http://www.grantprideco.com) our Annual Report on Form 10-K, Quarterly Reports on Form 10-Q, Current Reports on Form 8-K, and other information statements and, if applicable, amendments to those reports filed or furnished pursuant to Section 13(a) of the Exchange Act as soon as reasonably practicable after we electronically file such material with, or furnish it to, the SEC.
Item 2. Properties
      The following table describes the principal manufacturing, other facilities and offices we currently own or lease. We believe that our manufacturing facilities are well maintained and suitable for their intended purpose.
                 
        Facility    
        Size    
Location   Tenure   (Sq.Ft.)   Utilization
             
Drilling Products and Services
               
Navasota, Texas
  Owned     347,000     Manufacture of drill stem products
Veracruz, Mexico
  Leased     303,400     Manufacture of tool joints and drill pipe
Baimi Town, Jiangyan, Jiangsu China
  Leased     49,428     Manufacture of drill pipe
Jianjin, China
  Owned     100,912     Manufacture of unfinished upset to grade drill pipe
Turin, Italy
  Owned     60,400     Manufacture of tool joints
Jurong, Singapore
  Leased     33,600     Manufacture of drill collars, accessories, and threading services
Batam Island, Indonesia
  Owned     25,984     Manufacture of drill pipe
 
Drill Bits
               
Houston, Texas
  Owned     403,000     Manufacture of roller-cone bits
    Owned     50,256     Manufacture of fixed-cutter bits
    Leased     58,920     Manufacture of bi-center drill bits
Stonehouse, U.K. 
  Owned     71,000     Manufacture of fixed-cutter bits
Jurong, Singapore
  Leased     169,663     Manufacture of roller-cone bits
Provo, Utah
  Leased     39,038     Manufacture of PDC cutters
 
Tubular Technology and Services
               
Muskogee, Oklahoma
  Leased     195,900     Manufacture of TCA premium casing and premium threading
Houston, Texas
  Leased     249,893     Manufacture of Atlas Bradford connectors
    Owned     54,500     Premium threading services and manufacture of tubular accessories
Houma, Louisiana
  Owned     101,150     Manufacture and threading of downhole accessories
Broussard, Louisiana
  Owned     55,920     Premium threading of downhole and specialty equipment

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        Facility    
        Size    
Location   Tenure   (Sq.Ft.)   Utilization
             
Casper, Wyoming
  Owned     28,181     Premium threading of casing and tubing
Beaumont, Texas
  Owned     17,838     Premium threading services and manufacture of conductors
Vlissingen, The Netherlands
  Leased     65,800     Premium threading services and manufacture of conductors
Batam Island, Indonesia
  Owned     14,400     Premium threading services and manufacture of conductors
 
Corporate
               
Houston, Texas
  Leased     39,350     Corporate headquarters
The Woodlands, Texas
  Leased     61,831     Sales and administrative offices
Item 3. Legal Proceedings
      In the ordinary course of business, we are the subject of various claims and litigation. We maintain insurance to cover many of our potential losses and we are subject to various self-retentions and deductibles with respect to our insurance. See “Business — Other Business Data — Insurance.” Although we are subject to various ongoing items of litigation, we do not believe that any of the items of litigation that we are currently subject to will result in any material uninsured losses to us. It is possible, however, that an unexpected judgment could be rendered against us in the cases in which we are involved that could be uninsured and beyond the amounts that we currently have reserved or anticipate incurring for that matter.
Item 4. Submission of Matters to a Vote of Security Holders
      No matters were submitted to a vote of the stockholders of the Company during the fourth quarter of 2004.
PART II
Item 5. Market for Registrant’s Common Equity, Related Stockholder Matters, and Issuer Purchases of Equity Securities
      Our common stock has a par value of $0.01 per share and is listed and traded on the New York Stock Exchange (NYSE) under the symbol “GRP.” The following table sets forth for the periods indicated the high and low sales prices of our common stock as reported on the NYSE:
                   
    High   Low
         
2004
               
 
First quarter
  $ 15.99     $ 12.87  
 
Second quarter
    18.56       13.90  
 
Third quarter
    20.91       16.82  
 
Fourth quarter
    22.31       18.80  
2003
               
 
First quarter
  $ 12.81     $ 9.77  
 
Second quarter
    14.87       10.75  
 
Third quarter
    12.26       10.00  
 
Fourth quarter
    13.68       10.00  
      We have not paid cash dividends on our common stock since becoming a public company. We currently intend to retain any earnings for use in our business and do not anticipate paying cash dividends in the foreseeable future. In addition, our senior credit facility and indenture governing our 95/8% Senior Notes Due

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2007 and our 9% Senior Notes Due 2009 contain restrictions on our ability to pay dividends. Refer to Part II — Item 7 — “Management’s Discussion and Analysis of Financial Condition and Results of Operations — Liquidity and Capital Resources” for further information.
      At March 18, 2005, we had 2,815 record holders of our common stock.
Item 6. Selected Financial Data
      The following table sets forth certain of our historical financial data. Until we were spun off on April 14, 2000, we were a wholly-owned subsidiary of Weatherford International, LTD. (Weatherford). This information has been prepared as if we had been a stand-alone company during 2000. Additionally, in April 2004 we sold the assets and business of our Texas Arai division and prior year results related to this division have been reclassified as discontinued operations. This information should be read in conjunction with “Management’s Discussion and Analysis of Financial Condition and Results of Operations” and the Consolidated Financial Statements included elsewhere in this Annual Report on Form 10-K. The following information may not be indicative of our future operating results.
                                             
    Year Ended December 31,
     
    2004   2003   2002   2001   2000
                     
    (In thousands, except per share data)
Operating Data:
                                       
 
Revenues
  $ 945,643     $ 803,818     $ 609,390     $ 688,056     $ 451,659  
 
Operating Income (Loss)
    141,672       45,297       46,995       59,976       (11,029 )
 
Income (Loss) From Continuing Operations
    64,793       4,657       13,690       24,809       (14,716 )
 
Income (Loss) Before Cumulative Effect of Accounting Change
    55,266       5,190       13,046       28,090       (14,696 )
 
Net Income (Loss)
    55,266       5,190       6,634 (b)     28,090       (16,485 )(c)
Income (Loss) Per Share(a):
                                       
Income (Loss) from Continuing Operations:
                                       
   
Basic
    0.53       0.04       0.12       0.23       (0.13 )
   
Diluted
    0.51       0.04       0.12       0.22       (0.13 )
 
Net Income (Loss):