Carpet pattern matching seems like a no-brainer, a patterned carpet should match. At least this is the expectation of the end-user when they buy a carpet. Why shouldn’t carpet match, they purchased wallpaper and it matched.
Sometimes, carpet pattern matching is expected. Still, it just doesn’t happen, no matter how good the carpet installer is. Some patterns are random patterns. An example of this would be many sculptures that have an overprint and a printed Saxony style.
A salesperson needs to be aware of carpet pattern matching capabilities. Matching information should be discussed with the consumer at the time of sale. Additional material usually needs to be ordered to accomplish a match. The salesperson must explain this to the end user.
Carpet Pattern Matching: Dealer/Installer Responsibility
An installer needs to consider the time when bidding or being engaged for a job. A patterned carpet takes more time and skill to install than a plain-style carpet.
If an installer bids a job without obtaining product information in advance, they are not doing the job. At the same time, a dealer must supply product information to an installer. Otherwise, the dealer is also not doing their job. A mutual understanding about the consumers’ pattern matching expectations needs to be reached.
Extra charges should also be discussed before the carpet is installed. Matching is important to all concerned. Failing to have this discussion before installation is crucial. Ideally, it should happen at the time of sale. This often means the difference between success and failure.
Avoid Costly Mistakes: Carpet Matching Warnings
When a carpet is manufactured it goes through many processes like tufting, dyeing, printing and finished backing application. During any one or more of these processes, the pattern can end up wider or narrower. It can also become out of shape, making carpet pattern matching difficult at best.
Not all installers have the same amount of experience with matching patterns. Because of these manufacturing and installation peculiarities, many manufacturers give warnings that carpet pattern matching can’t be guaranteed. These warnings will be seen on sample labels and in product literature.
Carpet Stretching: Installer Standards & Expectations
The carpet installer is expected to adjust the pattern to obtain a match. This is acceptable as long as the distortion does not exceed manufacturing tolerance. The tolerance should also be reasonable.
An installer should verify the carpet pattern if they encounter a matching situation. They need to make sure that the pattern falls within the manufacturing tolerance of the product. This must be done before cutting the carpet.
During some installations, after one or more rolls have been cut, the pattern is found to run off excessively. This happens in the new role. In this situation, the manufacturer must be contacted before proceeding with installing the problematic carpet.
Installers and dealers often insist it was mandatory to finish the job. The consumer had to move in, and the manufacturer was closed. The big question here is if you knew that the job would need later replacement. Why did you fully adhere that section of the carpet through gluing or stretching?
In rare situations, there is absolutely no choice but to install and replace later. It is the dealer’s responsibility to reduce the replacement material and labor expense. An installer and dealer must always be aware. If they continue without consulting the manufacturer, they assume financial liability. This liability would rightfully belong to others.
Most carpet pattern matching can occur with good success, but needs a lot more time. Carpet pattern matching problems often occur when an installer specializes in residential work. These installers usually have little experience with commercial products and large installations. When this occurs, the installer has installed themselves into a difficult corner.
Carpet Pattern Matching Hints
- Whenever possible, (some manufacturers state “always”) “Row Cut” the carpet.
- Always “Dry lay” all pieces before starting the glue spread or hot melt process.
- Arrange all pieces to your best advantage thereby working the closest patterns together
- To find the best matching cuts, count 30 patterns first. Then compare the measurements to decide the sequence.
- Stretch the short pattern into register with the long pattern.
- Match and work patterns from the center towards the end.
- Do not mix dye lots as this can adversely affect the pattern match
Installation Tip: The Dead Man
An effective and ancient anchoring tool aids in pattern matching. It is called “The Dead Man, aka Deadman.” To make a deadman, take a 2″ x 12″ x 4′ board. Nail multiple rows of tackless strips to one side.
The deadman is placed with the tackless strip pressed into the carpet. An installer can then stretch off the deadman. A handle can be attached to it. Wrap with a piece of carpet for carrying and storage.
Carpet Pattern Matching Sidematch Conditions
- Incorrect Pattern Definition: Pattern specifications not designed correctly for the gauge of machine.
- Off Pattern: Pattern Changes in Dimension: High/Low loop or Cut/Loop. This manufacturing claim is caused by an error in equipment when reading the computer or film and/or clutch failure on the tufting machine
- Pattern Not Matched: You should conduct a visual inspection. Use measurements to decide if the pattern could have been matched. Was enough carpet available to match the carpet? What was the consumer told? These are questions you will need to answer to determine who is at fault.
Not All Printed Sculpture Carpet Will Pattern Match
The carpet is tufted with a highly visible sculptured pattern. This pattern repeats. A random dye overprint is used, which does not repeat with the sculptured pattern. With these carpets, this is a characteristic of the production process and not a manufacturing defect.
With this carpet style, you can’t match both the sculptured pattern and the dye overprint. You need to reduce seam visibility. Join the panels at either the sculptured pattern or “monkey match” the overprint pattern. Allow the sculptured pattern to fall wherever it will. Since both the pattern and print can’t be aligned, seams are visible. They may be more visible from one location than from another.
With most carpets of this style, the most acceptable appearance will be obtained by “monkey matching” the color pattern. It is usually impossible for the installer to fully match both patterns. The salesperson needs to inform the consumer that the seams may be visible. They must also order enough extra carpet for the match or “monkey match”.
Bowed, Skewed and Elongated Carpet Pattern Matching
Bowed Pattern: The pattern has an arc in it. This is due to greater tension in the center of the carpet than at the sides. The tenter was running at high speed. This caused the carpet to drag on the inside rollers while it was drying.
It should be determined before installation if the bow can be stretched out. If a bowed carpet is installed without the manufacturer authorization it will likely become an installation complaint.
Skewed Pattern: The pattern is on a diagonal. Pattern on one side of the tenter chain running at a different speed than the other can cause nap skew. As with bow, make sure it can be stretched out before installation so that it doesn’t become an installation problem.
Pattern Elongation: Pattern “mismatch” in integrated pattern carpets is called pattern elongation.
The patterns on one side of a seam are slightly longer than on the other. This difference causes the patterns to grow or elongate.
- Pattern elongation is figured as follows.
- Count a set number of patterns like 20.
- Measure the length of the number of patterns counted.
- Repeat the procedure on all cuts if uninstalled or on the joined panels if installed.
- Compare the measurements.
No manufacturer guarantees carpet pattern matching. A claim may be declined unless it is severe. The manufacturer instructed the installer or dealer to go ahead with the installation.
Definitions:
Drop Match: A pattern in printed, high-low, cut-loop, or figured woven carpet, which repeats diagonally. Each corresponding pattern element drops down a certain distance. It is usually a half pattern repeat in length. This is instead of simply repeating horizontally across the width as in set patch.
Monkey Match: When an exact pattern match can not be obtained, a monkey match occurs. This is done by matching the design to give the appearance of a match.
Random Match: A random match does not have a repeat, the design is applied in more of a hit-or-miss arrangement.
Register: Exact matching into positions the pattern or lines of the abutting panels of carpet
Set Match: A set match is a design that repeats at regular intervals on the same level across the width of the carpet
To find a Certified Carpet Installer, visit the CFI – International Certified Floorcovering Installers Association. You can also learn more about carpet installation. Additionally, the site offers carpet installation training and certification.
If any issues arise during or after your carpet installation, it’s crucial to seek expert assessment. An independent third-party inspection can help identify and resolve concerns effectively. In Washington and Oregon, TW Group Flooring Inspections specializes in thorough evaluations. For other locations, the National Institute of Certified Floor Covering Inspectors (NICFI) provides a directory of professionals who can assist.
