RFI - Dunnage Bar Manufacturing.pdf

REQUEST FOR INFORMATION (RFI)

Subject: Dunnage Bar Manufacturing Issuing Agency: U.S. Department of Transportation, Volpe National Transportation Systems Center RFI Reference No.: 6913G627RFI100 Date of Issuance: October 16, 2026 Response Due Date: October 23, 2026

1. Purpose and Objective

This RFI seeks information from qualified vendors regarding the feasibility, recommended approach, rough order magnitude, lead time, and any risks associated with manufacturing approximately 1,000 dunnage bars similar to the EVANS DF-1 loader crossbar. The intent is to gather information to inform a possible future procurement or contract.

2. Equipment Specifications and Background

The intended part is modeled after the EVANS pattern DF-1 Dunnage Bar, which is used to secure heavy cargo and equipment inside boxcars.

● The bars are telescoping on one end, allowing the overall length to vary between approximately 107” – 115”. The steel beam exhibits a “Z”-shaped 8-gauge steel cross section with ½” returns, bolted between two oak wood bars. Each end is fitted with a cast metal head and a pinned locking latch.

● Material: Steel and oak wood

3. Load Ratings

The manufactured dunnage bars will need to meet minimum load ratings as follows:

● Uniformly Distributed Vertical Load: 4,000 lbs.

● Concentrated (Center Span) Load: 2,000 lbs.

● Horizontal / Longitudinal Restraint Load: 4,000 lbs.

4. Scope of Capabilities Requested

Vendors should state in RFI response which steps they can support:

● 3D scanning of sample cast parts

● Casting of head and latch parts

● Machining of cast parts

● Bending of metal for Z-bar parts

● Machining wood parts

● Welding of cast head parts

● Assembly of dunnage bars

5. Technical Requirements and Component Dimensions

5.1. 3D scanning of sample dunnage bar:

● The cast ends of the bar will require accurate measurements for molds to be made.

● Once scans are made from an existing sample the scanned image will need to be digitally adjusted to compensate for aging of the sample.

● Vendors should note whether they will do the scanning in-house or contract it out.

5.2. Casting head end parts:

● Casting to be investment type casting or drop forged

● Locking pins to be hardened

● Castings to be zinc plated or commercial-grade black oxide

● Telescoping head to have cast tailpiece integrated with head

● Fixed head to have tabs that slot into main crossbeam to facilitate welding

5.3. Main crossbeam body:

● Constructed from 8-gauge steel

● Corrosion protected

● Bar notched and tube welded to bar for telescopic head

5.4. Wooden inserts:

● Hardwood (Oak preferred)

● Notches, hollows, etc. as indicated on sample

5.5. Miscellaneous parts:

● End plate welded to telescoping head end of main cross bar

● Spacer plates attached to wood beams on fixed head end

5.6. Dimensions:

The following rough dimensions are provided for estimating purposes only and are taken from a sample dunnage bar. Please note that the overall length of the bar and telescoping tailstock/tube will need to be changed to accommodate new dimensions.

Component/Feature Dimensions Notes/Specifications

Overall Length (Compressed) 110” —

Overall Length (Extended) 112 ¾” —

Pin Diameter 0.0627” (15.93mm) —

Pin Length 11/16” —

“Z” Bar (L x W x H) 103 13/16” L x 3 11/16” W x 3 9/16” H Return lips are ½” H

“Z” Bar Thickness 5/32” 8-gauge

Wood Bar 103 13/16” L x 2 ¾” W x 19/16” H

Features several notches, a lengthwise chamfer to fit under Z-bar return lip, and 7 countersunk holes for carriage bolts

Cast Head (Fixed End) 3 5/16” L x 3 3/8” W x H Head has asymmetrical height of 2 5/8” and 2 1/16”

Cast Head (Extendable End) 9 1/16” L x 3 3/8” W x 2 5/8” W —

Cast Head Material Thickness Varies —

Tailstock 6” L × 1 ¾” W × 1 13/16” H Measured from back of head to end; includes milled slots on both sides

Extension Bar Thickness 1 ¼” Measured without milled slot

Extension Bar Milled Slot 5 ¾” L × 0.564” W (14.34 mm) × 0.22” D (5.60 mm)

Secondary milled slot runs the entire length on the opposite side with identical width and depth -unclear if this is needed

Extension Bar Inner Tube Thickness ⅛” 11 gauge

"Z" Bar Tube Facing Plate 3 5/8” L Includes 1” right-angle bends on opposite sides; 1/8” thick (11 gauge)

Carriage Bolts 3 5/16” L (Overall) / 3” L (Body) × 9/16” Dia. —

Long Rivets 3 ¾” L (Body) × ¼” Dia. —

6. Dunnage Bar Photos

Side View

Top View

Bar in position

Telescoping end upside down

Telescoping end removed from bar (Note tailstock)

End latch (note spring steel)

Telescoping end top view with latch removed

Tube for telescoping end

Tube endplate for telescoping end

Fixed end upside down (note asymmetrical casting)

View of weld on fixed end

View of fixed end in position

7. Submission Instructions

Interested parties should submit a written Statement of Capabilities of sufficient detail demonstrating their experience and ability to provide said services as outlined in this RFI.

Information provided shall be detailed and shall show technical capabilities, knowledge, and expertise so the U.S. DOT can assess the ability to provide the described services in each of these work areas:

• Technical and Manufacturing Strategy:

o Proposed manufacturing/modification method(s).

o Welding recommendations.

o Quality control, inspection, and testing processes.

• Testing, Validation and Certification:

o Recommended testing (dimensional, NDT, tensile, fatigue, functional load test).

o Ability to perform FEA and provide analysis reports.

o Certifications held (ISO 9001, AS9100, AWS welding qualifications, NADCAP, etc.).

o Inspection and test plans (ITP) and sample acceptance criteria.

• Production Capacity, Lead Time & ROM Cost o Minimum order quantities.

o Lead time estimates and rough order magnitude costs for producing approximately 1,000 dunnage bars (Please note that this RFI request is non-binding, high-level cost information for budgetary planning purposes. It is not a bid solicitation and will not result in a contract.)

• Risk Identification:

o Identification of key manufacturing, supply chain, or technical risks.

o Standard warranty and quality guarantee terms.

• Additional Information Required:

o List of required drawings, information, or samples you need from us to provide a firm quote.

• Experience and References:

o Examples of similar work performed (brief description, photos).

All the information sought must be conveyed in no more than 10 pages. Page size is set at 8 x 11 inches, and text must be no smaller than 11 point. Graphics and images may be included within the 10-page limit. Text contained within graphics or images may be of any size so long as it is legible. Hyperlinks to external references may be provided but the information contained within the Statement of Capabilities should stand on its own. Each response must reference the RFI title. Interested vendors shall indicate their socio-economic small business size status (Total Small Business, 8(a) business development, historically underutilized business zone, service-disabled veteran owned, small disadvantaged, or woman-owned) in the appropriate North American Industry Classification System (NAICS) code. As a result of recent changes to the Federal Acquisition Regulation (FAR) Part 19, small business concerns must ensure that their status certifications are up to date.

Interested parties must respond to this announcement in writing by October 23, 2026, at 4:00 pm Eastern Time. Telephone requests will not be honored. All responses must be submitted via e-mail to Andrew Josephs at Andrew.Josephs@dot.gov. Electronic attachments to the e-mail must be submitted in Adobe PDF format.

8. Information Availability THIS NOTICE IS NOT A REQUEST FOR PROPOSAL. This notice is for information and planning purposes only and is a market research tool to determine the availability and adequacy of potential business sources prior to determining the method of acquisition and possible issuance of a Request for Proposal. The notice does not constitute a solicitation for bids, quotations, and proposals, and is not to be construed as a commitment by the U.S. Government.

The information provided herein is subject to change and in no way binds the U.S. Government to solicit for or award a competitive contract. The U.S. Government is not obligated to and will not pay for any information received from potential sources as a result of response to this RFI notice. The U.S. Government will not pay for any materials provided in response to this synopsis and submittals will not be returned to the sender. Submissions must be disclosable to the public, or the submitter should provide a summary statement that can be disclosed to the public with fuller supporting information that is clearly marked as restricted. The U.S. Government will use customary means to safeguard proprietary information, but only when such information is (1) clearly marked as proprietary; (2) is, in fact, information that could not have been obtained from another party or source; and (3) is otherwise deserving of such treatment under standards and processes described in the Freedom of Information Act (FOIA) and Executive Order 12600.

For information about the Volpe Center, refer to the Volpe Center website at https://www.volpe.dot.gov.

https://www.volpe.dot.gov/