No, adding rootdelay=180 doesn't solve the problem. I now have
configured the system not to start with a degraded array. Which results
in the boot process being interrupted by a initramfs/rescue shell. In
that shell I stop the raid (mdadm --stop /dev/md5) and re-assemble the
arrays: mdadm -A --scan, then exit the rescue shell and the system boots
fine with the raid fully operational and no hours of re-syncing. So it
seems to me that something affects the order in which the raid devices
are brought up. I've been trying different settings for the root delay,
even found some bios options to give the disks more time to start before
grub is started, but only manually stopping the degraded array and
reassembling the array from the rescue shell works so far.

Kind regards

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https://bugs.launchpad.net/bugs/990913

Title:
  RAID goes into degrade mode on every boot 12.04 LTS server

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