Carpets Wall to Wall

What You Need to Know About Carpet!

The Weinheimer Group Certified Carpet Inspectorsstorage cabinet
You are here: Home / Archives for Carpeting

Tufted Carpet Manufacturing Process

By 1 Comment

tufted carpet manufacturing process styleHow Tufted Carpet is Manufactured (includes video)

Prior to tufting machines and the tufted carpet manufacturing process most wall to wall carpets were produced on weaving machines. Beautiful designs and intricate patterns were achieved by weaving though the process was slow, making wall to wall carpet out of reach for many people. Today, the tufted carpet manufacturing process is used to produce the majority of all wall to wall carpet at a fraction of the costs of woven products.

Through the use of computers, the beautiful and intricate patterns that were once only seen in woven carpets can now be achieved by the tufted carpet manufacturing process. Computers can be programmed to determine the patterns, styles, construction, and density.

Some tufted carpets are manufactured using  yarn that has already been dyed. Some synthetic yarn is solution dyed and the color is built into the formulation used to produce the yarn. Other yarn is produced and then predyed using methods suck as skein dyeing. Most tufted carpet is manufactured using a greige yarn (undyed yarn). During the carpet manufacturing process, once carpet yarn is stitched into place, the carpet is dyed using a variety of methods that will create solids, patterns or effects.

All tufted carpets including cut pile start out as a loop. For cut pile carpet the loops are cut during the tufting process. The face of the carpet is sheared to its desired effect and a secondary backing is applied to the carpet. This secondary backing will give the carpet its stability and allow it to be stretched during the installation process. The following video will give you a better understanding of tufted carpet manufacturing including both tufting and dyeing.

Carpet Cushion Tests Methods for Evaluating Carpet Pad

By 2 Comments

carpet testing

Carpet cushion tests methods are used for the evaluation of carpet pad (cushion). The industry has developed a number of carpet cushion tests methods for evaluating carpet cushion. These evaluations have resulted in a better carpet pad being offered to the consumer.

Many wall to wall carpets will experience premature failure as a result of cushion (pad) failure. Unfortunately a large percent of those in the carpet industry that call themselves “professional” do not recognize when it is the cushion that has failed and not the carpet. When it is believed that a pad has failed there are carpet cushion tests methods for on-site evaluation. Expert-professional inspectors such as the Oregon based Weinheimer Group will be able to determine if it is the carpet or the pad that has failed.

Manufacturing Carpet Cushion Tests Methods

Evaluation of Cushion Density of Foam Style Cushion

To determine density, a one cubic foot (12″ x 12″ x 12″) of foam is weighed. The weight of this cubic foot is reported as (x) pounds per cubic foot.  This is a reasonably accurate test that is reporting the material’s actual substance, in this case the substance being the density.  The higher the density the better the support characteristics of the product.

Cushion Thickness

With cushion, thickness does not mean density.  Thickness is the measurement of the product from one side to the other as the product has been manufactured for use. Thickness is shown as a fraction of an inch or in its decimal equivalent, i.e., 5/32″,  3/8″, 7/16″, 1/2″, 9/16″.

CFD (Compression Force Deflection)

A measure of the load bearing ability of a foam.  It is the force exerted against a flat compression foot larger than the specimen to be tested.  The value can be expressed at 25%, 40%, 50% and/or 65% compression (ASTM D3574).  Note: Previously called “CLD” (Compression Load Deflection)

IFD (Indentation Force Deflection)

A measure of the load bearing capacity of flexible polyurethane foam.  IFD is generally measured as the force (in pounds) required to compress a 50 square inch circular indentor foot into a four inch thick sample, typically 15 inches square or larger, to a stated percentage of the sample’s initial height.  Common IFD values are generated at 25 and 65 percent of initial height. (ASTM D3574.) Note: Previously called “ILD” (Indentation Load Deflection).

Walk-on Testing

This is a standardized testing procedure that can be used by any segment of the industry from carpet manufacturers and cushion producers to distributors and retailers.  This test is used to evaluate installed residential carpet system performance. While this test can be used to evaluate different styles of carpet over a particular control system it can also be used to compare the effects of different types of carpet cushion on the composite floorcovering system.  The complete protocol for this test is available through the Polyurethane Foam Association.

Onsite Carpet Cushion Tests Methods (Field Evaluation)

Discoloration

The gradual yellowing of foam due to a photochemical reaction.  It is faster in sunlight than in artificial light, although it occurs in both.  Fresh foam may discolor in the center of the block as a result of thermal or chemical events.  Discoloration does not affect the physical properties of the foam.

Hard Spots – Resin

Spots that are hard like a marble are generally from the resin used in the bonding process. A spot that is hard enough to be felt is generally considered a defect.  The proper correction is to remove the spot.  A pad should not require replacement unless the spots are excessive.

Hard Spots – Skin

These are shiny, narrow, hard pieces that come from the outside of some foam buns. An inexpensive pad will likely contain more skin than a better variety.  Skin spots are a characteristic of many bonded urethane cushions and it is common for manufacturers not to consider them a defect unless they are large enough and hard enough to cause discomfort when walking in bare foot.

Mildew Problems

Slow seepage or flood that goes undetected or uncured for several days may result in mildew.  Fiber pads suffer this problem.  Rubber & foam are impervious, but they must still be removed because they retain water and the carpet backings are also liable to suffer from mildew.

Oxidation Problems

Rubber & foam pads depend on the sealing off of floor & carpet surfaces to prevent undue oxidation.  Areas with bad air pollution (NO2, O3) intensify problems.  Fiber pads are impervious to this problem.

Thickness

A cushion that is too thick will protrude above the tack strip and will not allow for a good grip of the carpet against the pins, and may also cause a valley to appear along the edges which can lead to excessive restretch problems.

CRI 104 states that cushion thickness should not exceed 3/8 inch (9.5 mm) for commercial installations, and CRI 105 states that cushion thickness should not exceed 7/16 inch (11 mm) for residential installations.  Whenever performing a claim where cushion failure or specification is in question, a sample of the cushion needs to be selected.

CRI Carpet Installations Standards 2011 states, Separate Cushion Selection: It is required that the cushion conform to carpet manufacturer recommendations for the specific product being installed. Failure to follow these recommendations for cushion may void manufacturer warranties. These recommendations may differ, depending on the style and construction of specific carpet. Cushion thickness for commercial carpet installations should not exceed ⅜ inch (10 mm.)

Weight or Density Problems

Rubber pads over 75 oz., or bonded urethane and foam pads of greater than 7/16″, especially less than 5.5 lb. density, while adding comfort to some customers, also lessen the life of the carpet by intensifying problems of delamination.

CRI Green Label Cushion Testing Program uses a variety of carpet cushion tests methods to evaluate carpet pad.
Carpet Cushion Consumer Guidelines, Carpet Cushion Council

Modular Carpet Tile Patterns

By 3 Comments

Laying Modular Carpet Tile Patterns

modular carpet tile patternsModular  carpet tile patterns a great benefit for those that want more than just a solid or quarter turned appearance. With modular carpet tile patterns it is possible to use virtually unlimited color combinations and designs.  When choosing modular modular carpet tile patterns there are a number of directions that the tiles can be turned, or adjusted to achieve a particular look. The more common patterns are quarter-turn, monolithic, brick, ashlar, non directional and duolithic. [Read more…]

Is Carpet Cushion Carpet Pad?

By Leave a Comment

Carpet Cushion, Carpet Pad, What’s the Difference?

Is carpet cushion carpet pad? Cushion, pad, lining, or underlay are all synonymous terms used to describe any type of material that is placed under the carpet. A cushion carpet pad adds comfort, absorb sold newspapers under carpethock, reduce noise, increase insulation, and improve the performance of a carpet.  While all of these names are synonymous and all of them are used, the preferred term in the carpet industry is cushion. [Read more…]

Carpet Shading, Footprints, Pooling

By 56 Comments

shading and pooling

Why is My New Carpet Turning Different Shades?

There are many types of carpet shading complaints. Carpet shading is a localized alteration in the orientation of the pile.  Shading occurs as the result of randomness in pile lay direction. Shading will be seen on both wall to wall carpets and rugs. The physical cause of shading is due to the difference between light reflection from the greater surface area of the side of the bent fibers, which appear lighter in color, compared to the greater light absorption and darker appearance of the more vertically oriented fibers.

As a result of this change in light reflection a carpet will often take on an appearance as if a portion of the carpet has changed in hue. When inspection lighting is applied over the shaded area, no actual change will be seen. Carpet shading can occur as temporary carpet shading, tracking, or pile reversal defined as follows:

Carpet Shading

Carpet shading is a normal characteristic of cut pile carpets, especially those with a smooth pile such as velvets and saxony plush. Carpet shading is considered an aesthetic quality of fine carpet and is not considered a defect. Shading is caused by light reflecting differently off of tufts that bend differently from footprints, vacuuming, etc.

A person that finds carpet shading objectionable should select a carpet with a denser construction, lower pile height, textured yarn. Examples would be textured saxony, frieze, and berber.

carpet shading and tracking

Carpet Shading is identified by areas that appear lighter or darker depending upon the direction they are viewed from. Brushing the pile with the hand will result in a change of shade.

Temporary Carpet Shading

A reversible, localized change in orientation of a carpets pile. Temporary shading is often described as a normal characteristic of certain cut pile textile floor covering.

Carpet Tracking

A gradual change in appearance of a carpet from the edge to middle of a narrow band caused by repeated walking over the same area which may result in a localized change in pile orientation and may be irreversible

Carpet Footprints

footprints on carpet

These are shading marks left by humans and animals walking across the carpet. They may be noticeable for a few minutes or a few days depending upon the texture and resiliency of the fiber. Most deep-pile and smooth pile carpets will show footprints.

Vacuum Cleaner Marks

These are shading marks left by the brush and/or wheels of the vacuum cleaner. They may be noticeable for a few minutes or a few days depending upon the texture and resiliency of the fiber. Most deep-pile and smooth pile carpets will show vacuum cleaner marks

 Pile Reversal

carpet pooling - watermarking

Pile Reversal (Watermarking, Pooling)

An irreversible, localized change in orientation of a carpets pile. The phenomenon has different names in different countries
Over time, areas of carpet may look as though someone has spilled water on various sections of the carpet, hence, “water marking.” Other names to describe the phenomenon include “pooling” and “highlighting.

Common Identifying Characteristics: Areas of carpet may look as though someone has spilled water on various sections of the carpet, hence the term water marking. Areas reverse in shade when viewed from opposite directions. Shade will appear to change when brushing with the hand. At the interfaces (edge of perceived change), the pile on either side will be strongly oriented in opposite directions. Conspicuous, irregularly shaped serpentine lines or “interfaces” will generally be located in or immediately adjacent to traffic paths. The traffic pattern may not precisely follow the flow of traffic, but will appear to waver randomly throughout the trafficked pile.

Type of Claim: While water marking may give a highly objectionable appearance it is considered a characteristic and not a defect. Replacing the carpet with a similar carpet of any fiber will likely develop in the same condition within a few months. The causes of this form of pile reversal have not been conclusively determined. Because it occurs almost exclusively in and immediately adjacent to trafficked areas, traffic appears to be a significant contributing factor; however, several environmental factors, e.g. static electricity, electromagnetic fields have also been advanced as possible contributing factors.
The Carpet and Rug Institute in its manual titled Pile Reversal (“Shading”, “Water Marking”), states……the only conclusion which can be drawn is that pile reversal may develop on the surface of some carpet after it is installed, and that pile reversal is not due to the materials which are used to produce the carpet, the manufacturing process, or any combination of these factors.

Selecting Carpet Tiles

By 4 Comments

Wall to Wall Carpet or Modular Tile

modular carpet tileBroadloom carpet is not the only carpet that can be installed wall to wall.  When in the market for carpeting for a high traffic area, keep in mind that carpet tiles are another alternative to stretch in carpet. Carpet tiles are available in a wide variety of designs, colors and materials.  Carpet tiles are manufactured by many of the same companies that manufacturer wall to wall carpet such as Shaw Carpet, Mohawk Carpet, Beaulieu Commercial, Interface Carpet, Milliken Carpet and others. [Read more…]

Carpet Sprouting, Sprouts, Tuft Loss and Holes

By 10 Comments

Carpet Holes Sprouting and Yarn Pulling Out

carpet sprouts, tuft loss, holessprouingDSC_1056My carpet is going to go bare! A complaint so often heard from consumers when they see  loose tufts, snags and carpet sprouting on their wall to wall carpet. Seeing the yarn coming out of their carpet says to them that the carpet is failing and there must be a manufacturing problem. Most carpet sprouting issues, high tufts or even holes in carpet are not manufacturing problems even though they are a carpet issue that needs to be addressed. At the same time, some tuft loss on a cut pile carpet is considered normal and is not a reason for alarm. When in question, expert certified carpet inspectors like Terry and Kevin Weinheimer of the Weinheimer Group can determine cause and if a simple correction is called for or a carpet needs to be replaced. [Read more…]

Woven Carpet Manufacturing Process

By Leave a Comment

woven carpet manufacturingHow Woven Carpet is Made (includes video)

Woven carpet manufacturing was once the standard in the industry. Today’s production using the woven carpet manufacturing process is small as compared to tufting. For many designers and  buyers throughout the world, woven carpets such as axminster, wilton and velvet continue to be their carpet of choice. [Read more…]

Why The Weinheimer Group?

By 1 Comment

Terry and Kevin Weinheimer Certified Carpet Inspectors.

Terry Weinheimer Kevin Weinheimer

Terry Weinheimer and Kevin Weinheimer of The Weinheimer Group, are respected Floor Covering Consultants and Certified Floor Covering Inspectors. Kevin and Terry are experts at preventing floor covering problems, identifying the cause of a flooring problems and claims resolution. Our services are available for most types of floor covering including carpet, laminate, hardwood, vinyl, VCT, linoleum, cork, concrete and most other flooring materials and installation systems.

[Read more…]

Helpful Information

Recent Posts

Recent Comments

Carpet Inspections

weinheimer small add

TWG Flooring Sites

LaminateFloorProblems.com

FloorCentral.com

Weinheimer Group

Schedule a Carpet Inspection