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