If you’re looking for high-quality stave lumber core, there’s really no better option than Western Core Company. We’ve been a leader in stave lumber core for more than four decades and have a proven process that results in a superior lumber core.
You can learn more about our process and stave lumber core product below.
Rather than making it out of waste, downfall, and low-quality scrap lumber like many companies do, we use lumber specifically for stave core. Our stave core is manufactured using high-quality ponderosa pine, douglas fir, and white fir. We use the entire board and take extra time to remove knots and other defects.
By using high-quality wood for our staves, you get increased stability and aesthetics. With fewer knots and a uniform thickness, the core not only looks great when all the staves are pushed together but also has fewer weak spots where it could warp, bend, or break.
Plus, it makes it smooth and knot-free easier to machine for hardware, so you can add handles, windows, and other attachments to doors and furniture without damaging the integrity of the core.
When it comes to gluing and bonding the staves together, we’re all about quality, efficiency, and sustainability.
We use a Type 1 PVA (Polyvinyl acetate) glue. This wood glue is fast-drying, fully waterproof, and designed to stand up to high temperatures in our drying process and beyond. It also dries clear — no yellowing — to protect the overall natural aesthetics of the wood.
We’re also proud to note that the glue we use in our stave lumber core is urea-free, which means it’s free from formaldehyde, which can be harmful to the environment. In some regions, there are regulations and standards in place that restrict the use of formaldehyde-containing adhesives in certain applications, especially those involving interior furnishings and construction materials.
The glue we use qualifies for LEED (Leadership in Energy and Environmental Design) points to meet green and environmentally friendly building initiatives set forth by the U.S. Green Building Council.
Once the staves are glued and pressed together into the desired rectangular shape, we use a state-of-the-art Radio Frequency (RF) press system. This is generally regarded across the wood products industry as one of the fastest ways to cure wood components after gluing.
The RF press system utilizes radiofrequency electromagnetic waves to heat and cure the adhesive, creating strong and efficient bonds in a short amount of time. It allows us to cure the core quickly so it can be processed and shipped to customers without delays
After pressing, the stave core needs to fully dry. The drying process helps to set the glue and remove excess moisture from the wood, preventing warping or other issues.
As wood dries out, it shrinks. That creates huge quality issues in buildings and wood products, such as doors, desks, and tabletops. To combat that, Western Core has a top-notch drying process to get the core to an optimal moisture content that exceeds industry and building standards.
We kiln dry the core after gluing it to a 6% to 10% moisture content. This helps eliminate telegraphing and other issues caused by shrinking.
After the stave lumber core has been assembled and gone through the drying process, it goes through a quality inspection. We look for defects, alignment, and other issues to make sure the product lives up to all standards and important regulatory requirements.
Once it passes the inspection, it can be shipped for trimming, veneer application, and more. This is the best part because we love seeing our high-quality stave core used in beautiful doors, windows, furniture, and other projects.
We can talk about our stave lumber core and manufacturing process all day, but you really have to experience it in person to appreciate the quality and craftsmanship. Request a free sample and see the Western Core difference for yourself.
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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