When it’s time to choose a stave core manufacturer, you probably have plenty of questions. We’re here to help, so reach out to us anytime! We’ve put together answers to some of the most frequently asked questions we get here at Western Core to help you!
Western Core is a proud manufacturer of stave lumber core for doors and furniture. We also manufacture laminated veneer lumber (LVL), another popular core option.
Good question. Stave core, also called stave lumber core, is a wood product made up of narrow blocks of wood (known as staves) arranged side by side. The staves are joined using adhesive and heat, then sanded to create a smooth, uniform, continuous surface.
At Western Core Company, our stave core is manufactured using quality lumber, including ponderosa pine, douglas fir, and white fir. While other manufacturers use downfall, knots, and scrap from a cut-up operation, we use the entire board and take extra time to remove knots and other defects to produce a high-quality, stable product with fewer knots and a uniform thickness.
Our stave core is glued together with a Type 1 PVA (Polyvinyl acetate) glue, then cured with a Radio Frequency (RF) press system and kiln dried. This process ensures optimal moisture content and quick, efficient delivery.
Stave core construction is commonly used in various applications where strength, stability, and aesthetic appeal are essential. You’ll find our stave core used for architectural doors, table tops, and custom furniture.
Stave core can indeed be used for load-bearing structures. Stave core construction provides excellent strength and stability, making it capable of supporting considerable loads when properly engineered and constructed.
That said, suitability depends on various factors, including the intended load, the specific design, and the type of application. Our stave core is used in doors carrying an American National Standards Institute (ANSI) and Window and Door Manufacturers Association (WDMA) Extra Heavy Duty rating.
At Western Core, we use high quality ponderosa pine, douglas fir and white fir sourced here in the United States.
Great question. We use a Type 1 PVA (Polyvinyl acetate) glue. This wood glue is fully waterproof/weatherproof, dries quickly, and stands up to heat through the drying process.
The glue is also urea-free and qualifies for LEED (Leadership in Energy and Environmental Design) points, making it an environmentally-friendly option as well.
Laminated veneer lumber (LVL) is an engineered wood product created by bonding together multiple layers of thin wood veneers with adhesive and drying to form large, strong, and stable structural members.
When it comes to door construction, the choice of core material can significantly impact the door's performance, durability, and appearance. Different core options offer various benefits, and the best choice depends on factors such as the door's intended use, location, and budget. Here are some common core options for doors:
Particleboard Core: Particleboard core doors have a core made from wood particles and adhesive compressed together. They are an affordable option and can be used for interior doors, but they may not be as durable as solid wood core doors.
Stave Core: Stave core doors feature narrow strips of wood (staves) that are glued together to create a solid and stable core. Stave core provides strength and durability, making it suitable for both interior and exterior doors.
Laminated Strand Lumber (LSL) Core: LSL is an engineered wood product made from wood strands and adhesive. LSL core doors offer enhanced strength, stability, and resistance to warping or twisting.
At Western Core, we’re committed to using environmentally-friendly processes and materials to limit our impact as much as possible.
We focus on reducing manufacturing and transportation emissions and reducing waste as much as possible. We are also adhere to Forest Stewardship Council certifications and more.
Visit these resources to learn more about our eco-friendly initiatives:
Western Core Company has been a leader in stave core construction since 1973. We have more than four decades of experience and have a proven process that results in a superior stave lumber core.
Our facility is located in Payette, Idaho.
Full address:
580 6th Ave. S
Payette, ID 83661
We were formerly located in Susanville, California.
We ship all over the USA. If you’re looking for international shipping options, please contact us.
Great question. We’d love for you to see our quality stave lumber core and LVL for yourself. You can request a sample through the form on our website. One of our representatives will be in touch with you as soon as possible!
Our samples are a great way to see our core in person, so you can make sure it meets the strict requirements for your products and customers.
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