• Thank you for your replies. It took some time but we've found a workaround and MS believes it is a bug and they are going to investigate further.

    The answer was found here:

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    http://connect.microsoft.com/SQLServer/feedback/details/357255/reporting-print-layout-error-index-out-of-bounds

    Scenario

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    The report needed to be set up with each different "policy holder" begining on a new page of the report and the header for the "policy holder" should only be visible on the first page of their group of policies.

    Issue

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    When trying to export report to PDF getting an error “Index was outside the bounds of the array”.

    Cause

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    The hidden property for the outermost column group, i.e. PolicyHolder was set to “True”.

    Resolution

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    Edited the report in BIDS, for the outermost column group, set the Visibility to "Show" and changed the Hidden field to “False” (which was previously set to True).

    Workaround

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    The report designer used floating text boxes for column groupings instead of using the combined tablix column groupings. Apparently there is a limit if there is more than one page per grouping.

    Hopefully this could help someone else. As I mentioned, this appears to be a bug and we will be notified if a fix is created. If so, I will post the fix here, also.