80082 Interior Prdcts_cat cvrs in.pgs
7/11/08
7:48 AM
Page 2
Kerfkore
A revolutionary bendable substrate material
that can be laminated flat and then cold
formed into virtually any shape.
Kerfkore is the best choice for doing fast
and accurate radius work.
Kerfkore provides for smooth and symmetrical inside and outside radii up to 3 1/2"
Kerfkore is a bendable substrate material
that allows horizontal or vertical grade
laminates, metals, 2-ply and phenolic
backed veneers to be laminated flat
and then formed into virtually any shape
without stress cracks, delaminating or
telegraphing.
Kerfkore is a nominal 4'x8' panel size
and is available in 1/4", 1/2", 5/8" and 3/4"
thicknesses. The core materials include
particleboard, MDF, plywood, FR and NAF
(no added formaldehyde). The face
paper is a black latex impregnated paper
and the product is also available with an
optional brown phenolic paper backer.
Because of Kerfkore’s unique construction,
excess material can be used on other
projects virtually eliminating scrap and
saving money.
Kerfkore saves time and improves quality
by laminating flat and machining flat prior
to bending. It is dimensionally stable and
holds its shape when formed with a series
of horizontal ribs.
Kerfkore is ideal for production
environments where repetitive products
are manufactured.
Photo courtesy of: CBR Woodworking
Kerfkore was designed for architectural
millwork, furniture, store fixtures, marine
and motor coach industries plus
applications as vast as one’s imagination.
80082 Interior Prdcts_cat cvrs in.pgs
7/11/08
7:48 AM
Page 1
KERFKORE SPECIFICATIONS
PRODUCT DESCRIPTION
Kerfkore is a very flexible product that can be formed into
curves and radii as required. Kerfkore consists of a core of
kerfed particleboard with a flexible latex impregnated paper
face and is available in a nominal size of 4' x 8'.
Kerfkore is also available with an optional rigid backing sheet.
This two-sided semi-rigid product uses a phenolic impregnated
paper backing sheet to keep the material stiff. Once the paper
between the kerfs on the back is removed the product will act
and perform as desired. This construction is identified with a
KK prefix in the item number.
PRODUCT CHARACTERISTICS
Kerfkore allows for the flat lamination of semi-rigid face
materials that can then be bent and formed into the needed
shape. Materials such as high pressure laminates (vertical,
post formable, standard), two-ply veneer, phenolic backed
veneer, metal, and other similar material works extremely
well with Kerfkore. The ability to laminate flat offers the
advantages of ease of positioning face material, uniform
laminating pressure, labor savings and improved quality.
Easy splicing method for additional width or length is simply
accomplished by aligning the core material and then applying
the face material. After lamination Kerfkore can be made rigid
by laminating another piece of material to the open side while
the part is formed to shape. This is easily accomplished using
a vacuum press or other forming method. The use of a PVA
adhesive for this lamination is preferred as this will provide a
very strong bond. After forming, edge banding can be applied
to the open kerfed edges to provide a finished product. Please
refer to our website www.kerfkore.com for complete
fabrications steps and demonstrations.
CORE OPTIONS
Kerfkore comes standard with a high quality particleboard
core. Other core materials are available as required. These
options include fiberboard, luan plywood, poplar plywood,
FR particleboard, NAF green particleboard and other different
core materials.
not required but can be used provided moderate pressure is
used. The use of a PVA adhesive with a cold press is also
acceptable. When using this method only 30-35 PSI is needed.
Appling too high of pressure can cause the glue to reduce the
flexibility of the black paper and could affect the bending of the
product. Note: Due to possible broad variations in both
adhesives and laminates, it is always recommended that a test
strip be made to determine the amount of pressure and
adhesive coat necessary to achieve the desired results.
TEMPERATURE CONDITIONING
Kerfkore should be acclimated to the same temperature as the
decorative face material being applied to it. If available, use the
guidelines recommended by the face material manufacturer.
STORAGE
All products should be stored flat with the face material side
facing up. Keep in a dry area and away from direct contact with
the floor to allow for air circulation.
HANDLING
Kerfkore panels can be rolled into a coil for ease of handling.
Keep the black paper face side out when rolling and be careful
to keep fingers clear to prevent pinching. The two-sided
Kerfkore panels may bend towards the black face side during
handling. This will not affect the use of the product as the
small surface puckers that occur are over the kerfed area
between the ribs and will not telegraph through when
laminating.
RATINGS AND TEST DATA
Flame Spread Testing Results: Standard Kerfkore KK5OPB with
48lb. density, 1/2" thick particleboard core has been tested in
accordance with ASTM-E84 tunnel test with a general purpose
laminate adhered to the surface with a solvent based contact
cement. The results of this test were Class B.
KERFKORE CLASSIFICATION
AND DIMENSIONS
Panel Nominal
Actual
Size Thickness Thickness Wt/SF
BENDING CAPABILITIES
Item #
The bending radius obtainable using Kerfkore is directly related
to the material that is applied to Kerfkore. Normally a vertical
grade laminate or a phenolic-backed veneer will allow an
outside radius of 3 1/2" to be obtained on 3/4" Kerfkore. A
smaller radius is possible when using 1/4" and 1/2" Kerfkore.
It is best to pre-test any materials before proceeding.
SK25PB Particleboard
48" x 96"
1/4"
0.27
1.3 lbs.
SK50PB Particleboard
49" x 97"
1/2"
0.52
2.0 lbs.
2.5 lbs.
5/8"
0.65
49" x 97"
SK62PB Particleboard
SK75PB Particleboard
49" x 97"
3/4"
0.77
3.0 lbs.
SK50LP Luan Plywood
48" x 96"
1/2"
0.49
1.6 lbs.
SK62LP Luan Plywood
48" x 96"
5/8"
0.61
1.9 lbs.
48" x 96"
3/4"
0.73
2.1 lbs.
SK75LP Luan Plywood
0.49
1.1 lbs.
1/2"
48" x 96"
SK50PP Poplar Plywood
SK62PP Poplar Plywood
48" x 96"
5/8"
0.61
1.4 lbs.
SK75PP Poplar Plywood
48" x 96"
3/4"
0.73
1.6 lbs.
1/2"
0.52
2.0 lbs.
SK50FF NAF Particleboard 49" x 97"
5/8"
0.65
2.5 lbs.
SK62FF NAF Particleboard 49" x 97"
SK75FF NAF Particleboard 49" x 97"
3/4"
0.77
3.0 lbs.
KK25PB Particleboard
48" x 96"
1/4"
0.29
1.3 lbs.
KK50PB Particleboard
49" x 97"
1/2"
0.54
2.0 lbs.
KK62PB Particleboard
49" x 97"
5/8"
0.67
2.5 lbs.
49" x 97"
3/4"
0.79
3.0 lbs.
KK75PB Particleboard
KK item number identifies added phenolic backer for two-sided
product
ADHESIVES
The black latex face paper will accept any contact cement
recommended for use with decorative laminates. Use of PVA
glue is also acceptable provided it will result in a somewhat
flexible glue line. It is recommended to do a test on a small
sample to determine compatibility.
LAMINATING PRESSURE
Kerfkore is designed to work with contact adhesive when
attaching your face materials. Firm hand pressure or medium
pressure with a J-roller works well. The use of a pinch roller is
Core Material
Curves Made Easy
Why Kerfkore Products are Superior to Bendable Plywood
Curves are now made easier by using the
Kerfkore product line. An engineered product
which bends easily and consistently every
time. Kerfkore requires less labor and
materials while providing the highest quality
results.
Until now, radius designs have meant working
with Bendable Plywood which can yield
inconsistent results when formed and usually
require substantial framework. There is also
substantial time invested in resurfacing the
face.
The “Old” Way
Curves Made Easy
Kerfkore
vs.
Bending Plywood
STABILITY
Minimal structure is required to
support the Kerfkore products
Core material is kerfed which provides
stability while kerfs allow the panel to bend
Panel components are engineered wood products
which are less affected by moisture changes
Constuction of product by nature is unstable
allowing it to bend
Usually extensive structure is needed
to hold product from moving
Rotary cut veneer is more affected by changes in
moisture and will vary in stability
CONSISTENCY
Thickness is calibrated so all
panels are consistent
Panels will bend uniformly due
to the calibrated kerfs
Surface requires no prep work prior
to laminating or painting
Thickness will vary within the panel
due to using rotary cut veneer
Panels bend irregularly due to
inconsistent material density
Face must be filled, sanded and treated
before it can be painted or laminated
FABRICATION
A reduction in labor can be realized due to less
framework and surface preparation requirements
Minimal structure is required to form into radius
Surface allows for application of veneers, HPL,
metal and other materials with little surface prep
A variety of core options available in different sizes
and thicknesses.
Labor cost can be intensive with need for stronger
framework and additional surface treatment
A more extensive framework and support ribs
are usually needed to support the panels
HPL can be applied over surface but may result
in dips and loose spots. Veneer will require
additional surface treatment
COST COMPARISON
Cost more than bending plywood
Can reduce needed labor to complete projects
Savings realized by requiring less framework
Customer receives a high quality product which
can be consistently duplicated
Very economical initial purchase price
Labor can get involved and run up cost of project
Material needed for framework can increase cost
Customer can have quality problems due to
later movement in materials which may result in
refabrication
Company
2630 Sidney Lanier Dr., Brunswick, GA, 31525
912-264-6496 phone 912-262-9763 fax 800-637-3539 toll free
www.kerfkore.com info@kerfkore.com