Kerfkore

FAQ

Kerfkore

What is Kerfkore?

Kerfkore combines our unique manufacturing process with our LTX Black Flexible Backer to create a highly flexible and extremely stable base layer that allows for fast and easy attachment of high-pressure laminates, veneers, metals and many other semirigid materials. When using Kerfkore, the decorative surfacing material can be applied while flat and then formed into the desired shape achieving a tightest radius of 3 1/2.

What are the benefits of laminating flat and then forming the desired shape?

Laminating flat is a faster and more consistent process. It’s easier to position the decorative face material and machine while flat than to apply a laminate and machine to an already curved surface. Kerfkore is ideal for highly quality, consistently repeatable processes.

How do I use Kerfkore?

Decorative surface materials should be applied to Kerfkore while flat and then formed into shape.

  1. Size Kerfkore to the desired finished dimensions.
  2. Apply the decorative surfacing material using a water or solvent based contact adhesive or standard PVA glue (not a cross linking type).
  3. Allow glue to fully dry according to manufacturer’s recommendations.
  4. Use a router to trim the decorative surfacing material to match the finished size.

What additional materials and tools are required?

  1. Water or solvent based contact adhesive or standard PVA glue (not a cross linking type).
  2. Flat smooth surface
  3. J-Roller
  4. Brush and or cloth
  5. Vacuum or Cold Press (Best to use when attaching with PVA glue)
  6. Router (Optional)

What decorative surfacing material is recommended for use on Kerfkore?

Best Options:

  1. High-Pressure Laminates (HPL)
  2. Phenolic Backed Veneers
  3. Two-Ply Veneers
  4. Metals
  5. Other similar bendable materials will likely work, but a small test should be done before proceeding on bigger projects.

Should I use a specific brand or type of High-Pressure Laminate (HPL)?

Most brands and types are acceptable, but due to its flexibility, a vertical grade HPL is preferred. A horizontal grade HPL will also work, provided it has the flexibility needed for the application. Best Practice: Test a small sample to determine if the selected HPL will perform as desired.

Should I use a paper backed veneer?

No. Due to the flexibility of Kerfkore, paper backed veneers will not provide the rigidity necessary to prevent telegraphing. If using a paper backed veneer, it MUST be 0.020″ or thicker.

Can I use a phenolic backed or a two-ply veneer?

Yes. A two-ply veneer with a perpendicular backer is preferred over a two-ply veneer with a parallel backer.

What sheet dimensions are available for Kerfkore?

Kerfkore is available in 48″ x 96″ and 48″ x 120″, but a 96″ x 48″ or 120″ x 48″ version can be easily created. When an 96″ wide section is needed:

  1. Cut the 96″ material into two 48″ wide sections
  2. Place the two 48″ sections side by side leaving a small gap in between to duplicate the normal kerf width
  3. Apply the decorative surfacing material to both pieces of Kerfkore
  4. You now have a new product that is 96″w x 48″h
  5. For more information on splicing visit Kerfkore Splicing Without Fasteners (Width) Guide

What thicknesses are available?

Kerfkore is available in thicknesses of 1/4″ up to 3/4″

How do I attach Kerfkore to a framework?

Kerfkore’s flat lamination process makes it easy to cut grooves or dados into the back of the base material, allowing it to easily fit over or against forming ribs. The grooves and ribs can be attached using a PVA glue and pins. Use a hot melt glue to help secure the parts until the PVA glue can cure. If you prefer not to cut grooves or dados, Kerfkore can be glued and then clamped into place.

What type of framework is best?

There are several options, but a framework with horizontal ribs is preferred. The ribs should be uniform, allowing Kerfkore to smoothly bend into the desired shape. Vertical ribs are only needed for positioning the horizontal ribs or providing a vertical seaming rib.

Why can't I attach Kerfkore to the framework and then apply the face?

If Kerfkore is attached to the framework first, the LTX Black Flexible Backer cannot uniformly position the ribs. The uneven attachment of the ribs may cause telegraphing.

Available core material options?

Standard Core: Particleboard

Optional Cores: FSC / Fire Rated NAF Particleboard, MDF, and Plywood

Available face material options?

Standard: LTX Black Flexible Backer

How tight can I bend Kerfkore?

Kerfkore will bend to a 3 1/2″ radius. The tightest radius depends upon the flexibility of the decorative surfacing material. Kerfkore will bend to a smaller radius provided the decorative surfacing material is flexible enough.

Can Kerfkore be used to make curved doors?

Yes. Kerfkore is an excellent choice for curved doors, its flexibility provides minimal resistance or spring back. The curve is formed and held by the face and back material. More detailed instructions and options can be found here: Kerfkore Doors with HPL Guide

Timberflex

What is Timberflex?

Timberflex combines our unique manufacturing process with our 1/8″ imported Italian Poplar Plywood Face to create a flexible and stable base layer that allows for easy attachment of high-pressure laminates, veneers, metals and many other semirigid materials. When using Timberflex, the decorative surfacing material is applied after the base material has been formed into the desired shape achieving a smallest radius of 5″.

How do I use Timberflex?

Timberflex can be installed using conventional fabrication methods. Laminates and veneers should be applied to Timberflex after forming into desired shape.

  1. Apply the decorative surfacing material using a water or solvent based contact adhesive.
  2. Ensure uniform adhesion with a J-Roller.
  3. Allow glue to fully dry according manufacturers recommendations.
  4. Use a router to easily trim the decorative surfacing material to match the finished size.

What additional materials and tools are required?

  1. Water or solvent based contact adhesive?
  2. Flat smooth surface
  3. J-Roller
  4. Brush and or cloth
  5. Vacuum Press
  6. Router (Optional)

What sheet dimensions are available for Timberflex?

Timberflex is available in 48″ x 96″ and 96″ x 48″. Custom sizes are available call 1-800-637-3539. For additional information on groove direction see barrel vs column visual:

What thicknesses are available?

Timberflex is available in thicknesses of 1/2″ up to 3/4″

How do I attach Timberflex to a framework?

Cut Timberflex to match framework. Use a PVA glue and staples to attach the Timberflex to the framework.

What type of framework is best?

There are several options, but a framework with horizontal ribs is preferred. The ribs should be uniform, allowing Timberflex to smoothly bend into the desired shape. Vertical ribs are only needed for positioning the horizontal ribs or providing a vertical seaming rib.

How do I attach the decorative surfacing material?

A suitable contact adhesive is generally the best option.

How do I splice Timberflex?

Timberflex cannot be spliced. For a spliceable material, see Kerfkore.

Why do you recommend using horizontal ribs in place of vertical ribs with Timberflex?

Timberflex will only form a uniform radius around horizontal ribs. Using vertical ribs, if not set back from the horizontal ribs can distort the uniformity of the radius. The use of a vertical rib is only necessary when making a vertical seam.

What decorative surfacing materials are recommended for use with Timberflex?

Almost any decorative surfacing material can be used. Options include:

  1. HPL
  2. Phenolic backed veneer
  3. Two-ply veneer
  4. Three-ply veneer
  5. Paperbacked veneer
  6. Metal
  7. Many other semirigid materials
  8. Italian Poplar Face can also be stained or painted

Should I use a specific brand or type of High-Pressure Laminate (HPL)?

Most brands and types are acceptable, but due to its flexibility, a vertical grade HPL is preferred. A horizontal grade HPL will also work, provided it has the flexibility needed for the application. Best Practice: Test a small sample to determine if the selected HPL will perform as desired.

Can I use a paper backed veneer?

Yes. Due to the 3-Ply Italian Poplar Plywood Face, Timberflex can be laminated with any type of veneer after forming.

What radius can I make with Timberflex?

Timberflex will bend to a 5″ radius. While a smaller radius may be obtainable, it is best to test before attempting a radius under 5″.

Available core material options?

Standard Core: Particleboard

Additional Options: FSC / Fire Rated NAF Particleboard, MDF, Plywood, and Italian Poplar Plywood (premium option)

Available face material options?

Standard Face: 3-Ply Italian Poplar Plywood

FLEXBOARD

What is Flexboard?

Flexboard combines our unique manufacturing process with a 0.090″ hardboard face to create a flexible and stable base layer that allows for easy attachment of high-pressure laminates, veneers, metals and many other semirigid materials. When using Flexboard, the decorative surfacing material is applied after the base material has been formed into the desired shape achieving a tightest radius of 8″.

How do I use Flexboard?

Flexboard can be installed using conventional fabrication methods. Laminates and veneers should be applied to Flexboard after forming desired shape.

  1. Apply the decorative surfacing material using a water or solvent based contact adhesive
  2. Ensure uniform adhesion with a J-Roller
  3. Allow glue to fully dry according manufacturers recommendations.
  4. Use a router to easily trim the decorative surfacing material to match the finished size.

How do I attach Flexboard to a framework?

Cut Flexboard to match framework. Use a PVA glue and staples to attach the Flexboard to the framework. Use a hot melt adhesive to help secure the parts until the PVA glue can cure.

Can I press a single-ply veneer onto Flexboard flat before forming?

Yes. A single-ply veneer or 10 mil paperback veneer can be attached to the Flexboard before forming shape. Use a cold press application with a minimum pressure of 125psi. A bending radius of 16″ may be obtainable using this process.

The hardboard face on Flexboard looks too slick to attach a decorative surfacing material. Is a certain type of glue recommended?

Flexboard does not use an oil-based hardboard face, contact adhesives and PVA glues are both great options.

How do I splice Flexboard?

Flexboard cannot be spliced. For a spliceable material, see Kerfkore.

Why do you recommend using horizontal ribs in place of vertical ribs with Flexboard?

Flexboard will only form a uniform radius around horizontal ribs. Using vertical ribs, if not set back from the horizontal ribs can distort the uniformity of the radius. The use of a vertical rib is only necessary when making a vertical seam.

What decorative surfacing material can I use on Flexboard?

Almost any decorative surfacing material can be used. Options Include:

  1. HPL
  2. Phenolic backed veneer
  3. Two-ply veneer
  4. Three-ply veneer
  5. Paperbacked veneer
  6. Metal
  7. Many other semirigid materials
  8. Hardboard face can also be painted

How tight can I bend Flexboard?

The tightest bending radius for Flexboard is 8″. While a smaller radius may be obtainable, it is best to test before attempting a radius under 8″.

What sheet dimensions are available for Timberflex??

Nominal dimensions of 48″ x 96″, 96″ x 48″, 48″ x 120″, and 120″ x 48″

What thicknesses are available?

Flexboard is available in thicknesses of 1/2″, 5/8″ and 3/4″

Available core material options?

Standard Core: Particleboard

Additional Options: FSC / Fire Rated NAF Particleboard, MDF, and Plywood

Available face material options?

Standard Face: Eucalyptus Hardboard

Econokore

What is Econokore?

Econokore combines our unique manufacturing process with a 2-ply product design for a flexible and stable base layer that allows for easy attachment of high-pressure laminates, veneers, metals and many other semirigid materials. When using Econokore the decorative surfacing material is applied after the base material has been formed into the desired shape achieving a smallest radius of 10″.

How do I use Econokore?

Econokore can be installed using conventional fabrication methods. Laminates and veneers should be applied to after forming.

  1. Apply the decorative surfacing material using a water or solvent based contact adhesive
  2. Ensure uniform adhesion with a J-Roller
  3. Allow glue to fully dry according manufacturers recommendations
  4. Use a router to easily trim the decorative surfacing material to match the finished size

How do I attach Econokore to a framework?

Cut Econokore to match framework. Use a PVA glue and staples to attach to the framework.

How do I attach a decorative surfacing material to Econokore?

A suitable contact adhesive is generally the best option.

Can I press a single-ply veneer onto Econokore?

Yes. A single-ply veneer can be attached to Econokore after forming.

How do I splice Econokore?

Econokore cannot be spliced. For a spliceable product, see Kerfkore.

Why do you recommend using horizontal ribs in place of vertical ribs with Econokore?

Econokore will only form a uniform radius around horizontal ribs. Using vertical ribs, if not set back from the horizontal ribs can distort the uniformity of the radius. The use of a vertical rib is only necessary when making a vertical seam.

What decorative surfacing material can I use on Econokore?

Almost any decorative surfacing material can be used. Options Include:

  1. HPL
  2. Phenolic backed veneer
  3. Two-ply veneer
  4. Three-ply veneer
  5. Paperbacked veneer
  6. Metal
  7. Many other semirigid materials
  8. Fiberboard face can also be painted

How tight can I bend Econokore?

The tightest bending radius for Econokore is 10″. While a smaller radius may be obtainable, it is best to test before attempting a radius under 10″.

What sheet dimensions are available for Econokore?

Nominal dimensions of 48″ x 96″, 96″ x 48″

What thicknesses are available?

Econokore is available in thicknesses of 1/4″ and 3/8″

Available core material options?

Standard Core: MDF

Available face material options?

Standard Face: HD Fiberboard

Additional Options: 3-Ply Italian Poplar Plywood

WORKLITE

What is Worklite?

Worklite reduces material weight up to 80% by capturing a lightweight core between two thin high-density faces, resulting in a strong lightweight panel with structural integrity. Core material is a dense closed-cell Styrofoam that provides moisture resistance, thermal performance and compression strength. Some panels can weigh as little as 12 oz/sf while still providing a 1/8″ plywood faced panel to achieve a 3/4″ overall thickness. Panels can be covered with high-pressure laminates, veneers, metals and many other semirigid materials as well as stained or painted.

How do I use Worklite?

Worklite can be installed using conventional fabrication methods.?

  1. Size Worklite to the desired finished dimensions.
  2. Apply the decorative surfacing material using a water or solvent based contact adhesive or a standard PVA glue (not a cross linking type).
  3. Allow glue to fully dry according manufacturers recommendations.
  4. Use a router to easily trim the decorative surfacing material to match the finished size.

How do I attach Worklite to a framework?

The Worklite rigid face materials provide the ability to use conventional methods of attachment. The use of glue, staples, nails, screws, and other similar fasteners will allow the panel to be physically and structurally attached to other materials.

How do I attach a decorative surfacing material to Worklite?

A suitable contact adhesive is generally the best option.

The hardboard face on Worklite looks too slick to attach a decorative surfacing material. Is a certain type of glue recommended?

Worklite does not use an oil-based hardboard face, contact adhesives and PVA glues are both great options.

What decorative surfacing material can I use on Foamkore?

Almost any decorative surfacing material can be used. Options Include:

  1. HPL
  2. Phenolic backed veneer
  3. Two-ply veneer
  4. Three-ply veneer
  5. Paperbacked veneer
  6. Metal
  7. Many other semirigid materials
  8. Face material can also be painted

How do I edge band Worklite?

There are a few ways to handle this:

  1. An edgebander can be used, it’s recommended to use a 2mm or 3mm thickness as this will give ? the impact resistance needed due to the heat and solvent based glue slightly melting the foam. The edgebanding will adhere to the face materials. Kerfkore Company can provide internal perimeter framing, see Custom Product.
  2. If it is necessary to use an edgebander with traditional edgeband thicknesses, remove or route out the foam edges and glue in a solid wooden edge.
  3. A third edgebanding option is to use a water based adhesive and apply edge banding by hand.

What sheet dimensions are available for Worklite?

Available in a nominal 48″ x 96″ and up to a 60″ x 144″ depending upon the face.?

What thicknesses are available?

Worklite is available in thicknesses of 1/2″ up to 3″

Available core material options?

Standard Core: EPS Foamkore

Additional Options: XPS Foamkore

Available face material options?

Standard Face: Eucalyptus Hardboard

Additional Options: 3-Ply Italian Poplar Plywood and Fiberboard

Beadboard

What is Beadboard?

Plain Beadboard is made using an MDF core with standard bead spacing of 1 1/2″ on center. Wood veneer faced Beadboard consists of a veneer face applied to MDF core. Veneer faces and panel thickness options are available. Beadboard can be applied over sheetrock, paneling or other flat surfaces. Beadboard can also be attached to wood stud walls provided they are straight and uniform.

Are other bead spacing options available?

Yes, custom bead spacing is also available upon request.

Can beadboard be painted?

Yes, Plain Beadboard is designed to be painted. It is suggested that all panels receive a prime coat before the topcoat is applied. A light sanding between coats with a medium to fine sandpaper is recommended. It’s best to do this before panels have been installed.

Can beadboard be stained?

Wood veneer Beadboard is ready for finishing. However, it’s recommended that the panels be lightly sanded with 180 grit paper to remove any raised grain due to moisture pick-up. Application of stain, sealer and clear topcoat is recommended with sanding between coats using 220 grit sandpaper.

What is the difference between MDF Beadboard and Plywood Beadboard?

MDF Beadboard is more stable and consistent than plywood beadboard. MDF beadboard does not have voids or warp.

Can 1/4" beadboard be directly attached to metal studs?

No, direct attachment to metal studs is not recommended. Apply drywall to metal studs and then apply the Beadboard. Thicker beadboard panels i.e. 1/4″ can be attached directly to studs.

Italian Bending Poplar

What is the Italian Poplar Plywood?

The Italian Bending Poplar Plywood is a flexible 1/8″ material that can be formed into curves and radii as required while providing a smooth face surface. It is produced under strict tolerances and high standards with superior quality Italian Poplar veneers. Its three-ply construction provides for a stable product while still allowing it to bend into desired shapes.

What products can this face be applied to?

The Italian Poplar Plywood is a face option for Timberflex, Econokore, and Worklite.

HD Fiberboard

What is the difference between HD Fiberboard and MDF?

Since there is more density in HD Fiberboard, it creates a harder, stronger face than MDF. As a thin face material, HD Fiberboard is durable enough to bend, while MDF would break. This allows us to use HD Fiberboard as the face material for Econokore.

GENERAL PRODUCT QUESTIONS

Why should I use Timberflex or Flexboard in place of bending plywood?

Both Timberflex and Flexboard are dimensionally sized to have uniform thickness whereas bending plywood varies in thickness. Our products are free of odors. The face material on both Timberflex and Flexboard require no preparation before applying your face material. Only one layer of Timberflex or Flexboard is required to give you a durable quality product.

What is the difference between 48" x 96" and 96" x 48"?

The difference between 48″ x 96″ and 96″ x 48″ is the direction in which the board will bend. When bent a 48″ x 96″ will stand 96″ tall and wrap like a column. The 96″ x 48″ panel size will stand 48″ tall and wrap like a barrel. The second number also designates the direction of the grooves. On a 48″ x 96″ the grooves run the 96″ length and on an 96″ x 48″ they run the 48″ length.

Can you use these products to make doors and columns?

Yes, all products can be used to make doors or columns depending on the radius required. Please consult our technical manuals for step-by-step procedures for door fabrication or contact us at 1-800-637-3539

Can any of the bendable products be directly attached to drywall?

No, we do not advise applying any of our bendable products directly onto drywall.

Where can I purchase your products and how much do they cost?

Our products are available through an extensive North American distributorship program. Please see Find A Distributor to find a Distributor in your area. The distributor will provide pricing and availability. If there is not a distributor available or you have questions regarding the product, please check with our Customer Service Representative at: 1-800-637-3539.

Environmental

What is the California formaldehyde regulation?

In April 2007, the California Air Resources Board (CARB), a department of the California Environmental Protection Agency, voted to implement new limits for formaldehyde emitted from composite wood products. These new limits were fully implemented in 2012, the regulation established the toughest production standard in the world for formaldehyde emissions from composite wood products.

The California regulation governs the formaldehyde in both raw composite wood panels and finished products sold or used in California. Both imported and domestic products are regulated and must be third party certified and clearly labeled to indicate they meet California’s requirements.

What composite wood products are covered by the regulation?

The regulation applies to hardwood plywood, particleboard, and medium density fiberboard (MDF) and all products (such as furniture, cabinets, flooring, store fixtures, moldings and millwork, countertops, decorative household items, doors, etc.) made with those products.

What is formaldehyde?

Formaldehyde is an organic compound that exists naturally in food, the environment, and our bodies. It is biodegradable and is broken down through the energy of the sun, biological functions in the human body, and by organisms naturally found in soil and water. Formaldehyde?s versatility has made it an essential ingredient in the manufacture of products ranging from household cleaners to vaccines.

Why is formaldehyde used in composite wood products?

Formaldehyde’s prevalence and reactive nature make it an ideal ingredient in adhesives, as it crosslinks with other ingredients to form a strong, cost effective bond. For decades, formaldehyde has been used to produce most of the adhesives used in composite wood products.

What is CARB's Mission?

CARB’s mission is to ensure the best possible air quality for the citizens of California. To achieve that mission, CARB continuously monitors sources of air pollution in the state and acts to reduce emissions whenever possible. To that end, CARB has established formaldehyde emission limits for composite wood products at the lowest levels feasible with current technology.

General

Can I kerf my boards on the CNC machine?

By kerfing on the CNC, you are putting a lot of wear and tear on the machine. These are expensive machines and can be better utilized for other tasks. Actual kerfing is only a partial cut in the board, thus will not give you a true and consistent bend or radius. You will still have an amount of wood left in each cut. KERFS TELEGRAPH TO THE FACE. Flexibility varies consistency is hard to maintain. Radius is difficult to determine.

Can I do my own kerfing by hand?

Time consuming ties up manpower. Labor intensive = added expense. Typically, there is a lot of variation in the cuts: Space between and in depth of cut. Results in: telegraphing, variable flexibility, difficulty in determining radius, hard to maintain consistency and uneven surface requires additional treatment.

Can I use bendable plywood (Luan, Wiggle Board, Rubber Ply, etc.)?

Thickness varies, veneer quality is inconsistent, usually requires 2 layers, limited stability, inconsistent flexibility, additional surface treatment is required; framework is labor intensive requiring a lot of vertical ribs to hold shape and minimize imperfections on surface, such as cracks and dips; face material can only be applied after fabrication.

Can I use pre-formed shapes or corners made from MDF?

When using a pre-formed rigid shape or corner (usually MDF), you have to build around the pre-formed shape, since it is inflexible; limited sizes and shapes, large quantities required for custom shapes, hard to machine into smaller sizes, high waste potential.

Can I layer sheets together such as 1/8" poplar/birch or MDF?

A lot of glue required between layers = extra time, labor and expenses; requires expensive press equipment; special forms are required to press into shape; these forms are hard to make and have high cost; variable thickness; difficult to machine and sand after forming; difficult to hold correct radius, normally not used with HPL, most face material must be applied after fabrication.

Can I use veneers?

Yes, veneers work great with our products; veneer will work well with Flexboard, Timberflex, and Econokore.

What if I don't need a full sheet and don't want to have wasted material?

Our Kerfkore product allows you to use the amount you need and can be spliced for future projects without wasting materials. You are more likely to have more waste and labor using other methods and materials.

Glossary

Barrel Bend: This term is used to describe the 96″ x 48″ panel size. It will stand 48″ tall and wrap like a barrel. The grooves will run the 48″ length.

Biscuit Slots: Biscuit slots are cut into the side ribs of both the curved panels for attachment. Once they are aligned with their opposite half, insert the biscuits using white glue and strap the two column cover halves in place.

Butt Joints: This is an attachment method that could be used with our products. A butt joint is created by extending the laminate beyond the end of the panel to allow the corner panel to butt up against it.

Column Bend: This term is used to describe the 48″ x 96″ panel size. It will stand 96″ tall and wrap like a column. The grooves will run the 96″ length.

Dado Cut: This cut will be made through the center of the panel, so that a horizontal rib can be placed into it. This creates additional support for the structure.

Easy-Splice: This method is accomplished by easily splicing Kerfkore in length or width to utilize small pieces to make larger and/or unique sizes. The purpose of Easy-Splice is to eliminate scrap and use 100% of the material. This method can only be used with our Kerfkore product.

Kerfing: The process of cutting grooves or slots into a solid board.

Rabbet Joints: This is an attachment method that could be used with our products. This is a cut made into the top and/or bottom of the panel to allow the rails of the framework to be placed into it.

Ribs: Ribs are a supporting piece of wood that is cut to represent the shape of the end product.

Telegraphing: Telegraphing occurs when the ridge lines start to appear through the face due to the bending of the product. Because Kerfkore products are through cut, there is no transference of the cut edges to the face of the product. Kerfkore also uses a proprietary paper to separate the cut core and the face.

Veneer Checking: Cracks that appear on the surface of veneers.