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Carpet and Area Rugs


Major Carpet Subjects.

Fibers Construction Dye Methods Padding Air Pollution?
Store Measure Installation Area Rugs Warranty


Carpet accounts for about 75% of all flooring purchases in the U.S. Carpets and rugs are used for their decorative qualities of color and design. Carpets and rugs will cushion the floor, act as a sound deadener, and help thermally insulate the floor. I am amused when carpet only sales people say that carpet saves on energy costs. They must have vacuum cleaners powered by hamsters. A floor that is swept verses carpeting that should be vacuumed is a trade off decision based on one's lifestyle, energy costs in your area, and comfort. Carpet is big business, and therefore, big money. Of course, big money can bring out the best in most people and the worst in a few people. Information is the key to sorting the two. The problem in buying carpet, for most people, is lack of knowledge and experience. Obviously, knowledge is the key to good decision making. Knowledge is why you are at this web site. I hope not to disappoint you. For experience, well what can one do? Home owners buy new carpet about every seven to ten years, long before the carpet wears out. Ten years is a long time for the industry to develop new trends. The insider information on this page may help you catch up with the carpet and rug business.

If you are just looking for cleaning advice, please go to my Links page for industry sites that have up to date information.


FIBERS

Carpets and area rugs are made from five types of fibers; Nylon, Polyester, Olefin -- (Polypropylene is one type of Olefin), Wool, and Acrylic. A sixth fiber, Cotton, has limited use.

NYLON - (more than half of the carpeting sold in the U.S.)

Nylon ,(typically made from a dicarboxylic acid and a diamine), is a tough synthetic fiber with excellent resiliency, (ability to retain shape after being walked on). The latest generations of nylon carpets have good stain resistance. Nylon color possibilities are practically endless. The best way to keep the color is to SOLUTION DYE the raw polymer, then make it into a fiber. A good solution dyed commercial nylon carpet can be smeared with household chlorine bleach without showing loss of color. As you might have already guessed, solution dyed nylon carpets are more expensive to make. A residential nylon carpet is most likely given color by CHEMICAL BONDED DYEING, (yarn, continuous, piece, print, or stock dyed, depending on when the dye is used in the manufacture of the carpet). I have sold a lot of YARN DYED carpet where the nylon yarn is placed into a vat with the dye and "cooked" under heat and pressure - then the fiber is clear coated to keep out stains that can enter minute cracks in the fiber. The yarn is then made into carpet. Unless you have a compelling reason for using solution dyed carpet, you will find yarn dyed carpet the better consumer choice.

As with most fibers, synthetic or otherwise, there are differences in the quality or characteristics of the nylon fibers depending on how each was made. Chemically, there are different nylons only some of which are suitable for carpets. The nylon fiber thickness and number of fibers per strand can be different. Treatments like heat setting the twist, add-ons like clear coatings, and add-ins like monofilament polymeric conductors to eliminate static electricity, are all manufacturing variables in the carpet makeup and cost.

POLYESTER

Polyester is a synthetic fiber that is softer and less resilient than nylon, but costs less to make, (it can even be recycled from plastic bottles and the like). (One ester is made by reacting an acid with alcohol or phenol, then use the process of polymerization to make the complex ester we can walk on) Polyester can be easily solution dyed to allow harsh solvent cleaning, so it has excellent stain resistance for a lower price than nylon. Polyester is often made in bright, vibrant colors. The newest generations of polyester carpet, made in high density Berbers to resist matting, are quite good for family rooms. Some people like the feel of soft polyester fiber in a low density-high nap saxony carpet in their bedroom.

OLEFIN (Polypropylene) -- (about 30% of the carpeting sold in the U.S.)

Olefin , (unsaturated open-chain hydrocarbon with one or more double bonds), is a strong synthetic fiber you will find in the berber section. Polypropylene will not absorb water, (I use this fiber in a winter running shirt to whisk the perspiration away from my body). The fiber will be dyed with limitations to achievable colors. No additional treatment is needed to make the carpet stain resistant. In a carpet, Olefin is a tough fiber used in high traffic areas and some outdoor carpets. The feel is not as soft, and the color selection not as varied, as in Nylon or Polyester. However, with large looped, multi-colored berbers, Olefin can seem soft to the touch and coordinate in most color schemes.

TIP: A good manufacturer will spend the time to have experts chose among the colors and textures available to have the best looking Olefin carpet and carpet samples possible. If the line of samples look dull and uninteresting in the store, any carpet you may buy from that line will also look dull and uninteresting. Move to a better line, even with the same manufacturer.

TECHNICAL NOTE: Olefin is a generic name for paraffin based fibers. Polyethylene and Polypropylene are both Olefin fibers. So, if a carpet is labeled Polypropylene, then polypropylene is the pile fiber. If a carpet is labeled Olefin, it is possible that it is mostly polypropylene with some polyethylene fibers mixed in with the pile fibers.

WOOL - (less than 3% of the carpeting sold in the U.S.)

Wool used in carpet is normally from fleece, (sheep hair), but in antique rugs the wool can also come from other animals like goat hair, etc. For this page, the term wool will refer to the yarn made of fleece. Wool is a natural fiber with good resiliency, a soft luxurious feel, and high bulk. It is the standard that synthetic fibers are compared to. Wool can be left the color of the sheep, or dyed to different colors. (Dyed wool will have highlights just like any other dyed hair. This enhances the luxurious appearance or wool.) Dolly is a cloned sheep. Why not flocks of red and yellow sheep to go along with the flock of blue sheep that already exists? We'll see.
Wool is obviously more expensive than the other fibers due to supply and demand. Wool carpets wear well, and really do age beautifully. Wool carpets have a look and feel that is unmistakably their own. However, Nylon and Olefin carpets will last longer in high traffic areas.

ACRYLIC

Acrylic is a synthetic fiber , (polymerized acrylonitrile, CH2=CHCN, nasty stuff while liquid but an excellent monomer that mixes well with other monomers), that has a similar feel and look of wool, and will often be blended with wool to reduce the cost of buying a pure wool carpet. Acrylic resists the build up of static electricity. All Acrylic carpets and area rugs, (particularly with rubberized unitary backing), make excellent bathroom floor coverings, as they resist mildew and perform well in heavy moisture conditions.

COTTON

Cotton does not make successful carpet pile, but is fine for rugs that can be dried. Cotton fibers are soft to the touch, and are strong in and of themselves. However, cotton fibers also can absorb and retain many times their weight in water, (great for clothing -- not carpeting). Cotton holds water well. Water in carpet holds dirt. Dirt in carpet accelerates the breakdown of the carpet and pad when walked on, (like rubbing sand into it). Cotton fibers wear badly as carpet pile.

You will find cotton used well in area rugs that can be lifted off the floor and dried out. Cotton yarns do wash well and are highly absorbent. Cotton is made into small area rugs, such as braided cloth rugs, that can be washed and dried easily. Some woven rugs have cotton as the warp fibers, (particularly antiques and imports from certain countries). Cotton is useful as fringe.


CARPET CONSTRUCTION

FLOCKED carpets are made by electostaticaly binding fibers to a backing.

KNITTED carpet is made by numerous knitting needles interlocking pile and backing yarns, then a latex coating is applied to the backing to bind tufts firmly. When installing a Knitted carpet, do not try to stretch along the width and only delicately along the length.

NEEDLE-PUNCHED carpeting is made by, you guesed it, needles punching bating into a center fabric. This forms a flat fabric like carpet mainly used for indoor-outdoor carpeting.

TUFTED carpet , (the most purchased kind of carpet), starts with a pre-made fabric called the primary backing. The tufting machine quickly moves the primary backing past a bank of needles that insert tufts of pile yarn into this fabric. A latex adhesive is used to bind the tufts, (and usually attach a secondary backing to the primary backing). The 'new carpet smell' is from this harmless latex adhesive.

WOVEN carpets can be identified by the names of the looms used to make them. The three most important weaving methods for carpet are Axminster, velvet, and Wilton. As with the Knitted method, Weaving simultaneously interlocks the pile and backing yarns. A Woven carpet cannot be stretched along the width, but can be stretched about two inches along the length of an average size room.

TYPES OF BACKING

UNITARY BACKING has no webbing. Each loop is glued in and is tougher to zipper, but is good for seaming. It is installed by latex glue down only. NO STRETCHING.

ACTION BACK is Tufted, like needle point. It is kicked like residential carpet, and can be glued down.

ENHANCED BACK, (cushion-backed, or other names), has foam and/or felt glued to the carpet, and that IS the padding. The seams lock in like Unitary Back carpet. It is installed by glue down only. NO STRETCHING.

MOST CARPETING IS TUFTED into a primary backing fabric, then a latex adhesive is used to attach a secondary backing. It is the secondary backing that you see when you flip over the carpet sample.

CARPET TILES can be constructed in different ways, but are by definition "tiles". Carpet tiles generally cost about double a normal carpet of comparable durability, (installed price anyway). The tiles might be one and one-half feet square or two feet square. Tiles take longer to install. There is reusable glue available for moving the tiles around, rotating tiles through high traffic areas to stretch out life of the carpet. The glue and tiles cost more, but it is worth the extra expense for some applications, like public buildings.

CARPET PILE FINISHES

Most carpet starts as loops of yarn, tufted or otherwise, then the loops are either cut or left as loops, or both. (Huh?) Cut pile, Loop pile, or Cut and Loop pile. I am not yet referring to colors of yarn. When the carpet surface has different heights of yarn, it is called SCULPTED carpet.

CUT and LOOP PILE carpets combine both types of yarn ends, and is normally used for sculptured carpets.

COMPARING CARPET FEATURES

When you shop around, (as you should), comparing carpet to carpet by the feel may not be so accurate. I use the manufacturers own ratings of Face Weight, Density, Twist or Tuft Bind, and of course- Fiber Content. If the store does not have that information, ask them to get it before you commit to a measure. If the store will not provide you with this information--walk away! There are so many ways to make a carpet that effect performance, durability, and price that you can find just about what you need in most price ranges. As you shop around you will gather in your mind what you are willing to compromise on to fit your project and budget. Always take the final sample choices home to see what they look like in the setting to be carpeted. The color will almost always be different than in the store. Also, the over all look of the carpet sample may not be what you had in mind. Samples allow you to stretch your imagination as to what kind of carpet type and look you might use. Please take samples home. (Sometimes a bargain carpet just looks cheep, and do you really want that in your home? There are inexpensive carpets that look good. But, they will not last as long.)


DYE METHODS

SOLUTION DYE means to mix dye stuffs with the raw polymer, then make it into a fiber. Colorfastness is achieved by integrating the pigmentation into the structure of the yarn fiber itself. This allows for harsher cleaning methods on the carpet, even some mild solvent use. Please use only the methods recommended by the manufacturer because you could effect other parts of the carpet, like the latex on the backing or the clear coat around the fiber. The main thing about cleaning a carpet is to rinse, rinse, and rinse again until you are bored stiff.

CHEMICAL BONDED DYEING may be labeled continuous, piece, print, stock, or yarn dyed, depending on when the dye is used in the manufacture of the carpet. The dyestuffs are topically applied to the yarn, whole carpet, or carpet surface. Harsh cleaning or heavy commercial traffic may show gray spots in the carpet by wearing off the color. Think of the colored fiber like a carrot or a radish, (dull in the exact middle).

For both Continuous and Print Dye methods, the manufacturer can pack a warehouse full of white looking carpet ready to except dyestuffs. Then, make more of any color or pattern of carpet that proves popular in the marketplace, (reducing waste). Also, customers can make special orders of carpet of these types with less expense than would be expected with more durably dyed carpets. "Customers" in this context would normally mean large retail chains and other corporate accounts, but this could mean you too.



PAD TYPES FOR CARPET AND RUGS.

I tend to group carpet padding under three major headings, (felt, foam, and rebound), but the industry uses the terms- Prime Urethane, Densified Urethane, Grafted Urethane, Bonded Urethane, Flat Rubber, Rippled Rubber, and Felt for classifying cushion types.

All padding is described by thickness, the maximum should never be more than 1/2 inch with few of us recommending anything above 7/16 inch. Padding for loop pile carpets should not be thicker than 1/4 inch as excessive vertical movement when walked on will break down the carpet faster than intended.

This could be important to you if you are specifying a carpet job for a public building or a HUD project. Also, warranties can be effected by the wrong choice of padding. The Carpet and Rug Institute has established standards for installation that your retailer should follow, (if you have any doubts-ask and/or demand information or please go elsewhere).

Padding will increase the longevity of the carpet, improve both sound and thermal insulation, prevents carpet slipping, and cushions the carpet to make walking on it more comfortable. "Cheep" pad will coast you more in the long run. (If it looks like thin packing foam, it is cheep.)

Pad comes in different widths, typically six foot wide and four foot wide. The pad is normally seamed with duct tape. The seams should never run along under the carpet seams, but crossing underneath is fine.

FELT or HAIR padding has good firm support. It is used in many commercial jobs in public buildings because it meets stiff fire codes, and wears well. Usually, it is not as mildew-resistant, or stretch resistant, as other pads, and can be less comfortable to walk on over many hours.

FOAM pads should not lose more than half their height when you pinch them. I generally do not like urethane foam pads. I call rubber pads "foam" because there is nothing else in them but air. Rippled or waffle rubber pads allow for better air flow then smooth rubber pads. (NOTE: Just after the oil crisis of the late 70's, some pad manufacturers put clay filler into rubber pads to save money. Unfortunately, the pad would eventually release the clay. If your old carpet is always dusty, even after vacuuming, you may have this kind of pad.)

REBOUND pad, (the most used residential padding), is made of bits of urethane foam bonded together. Usually a web of fishing line-like thread is fused to the top of the pad, (this side faces the carpet). The multi-colored look of the pad has to do with the available urethane pieces, so the overall color is not an indication of the density or thickness of the pad. Normally I would recommend a 1/4 inch, six or eight pound pad for berber carpet and a 7/16", (no higher), six pound pad for saxony carpet. Berber carpets have continuous filaments, so a pad higher that 1/4 inch will allow premature breakdown of the carpet.

Some people ask why the estimate includes the same amount of pad as carpet when there will be some waste in the carpet. Well, it is common practice to include the same amount of pad for several reasons. Pad is not easy to work with. There will be wasted pad as well. Installers are not given instructions as to pad placement like they would be for carpet, (for seams and use of waste from main areas on stairs, etc.), so installers like to have a workable amount of pad on hand. Also, carpet remnants used by the customer should probably have padding as well. Pad is not expensive, (except rubber pad), but if the estimate of waste is in excess of 15%, then talk to your salesperson about cutting back on pad. (Five to ten percent is OK)

PADDING for AREA RUGS fall into two categories, rug over carpet and rug over hard surface flooring.

Normally, area rugs are made in such a way as to not harm what they are placed over. However, if you slip even once, you should consider using padding. Padding for area rugs is often sold in pre-set dimensions, like five feet by eight feet or two feet by four feet and/or other common dimensions. You simply cut the pad to measure with scissors to about an inch short of the edges of the rug.


Air Pollution?

'It's not the new carpet, it's ripping out the old pad!'

Having wall-to-wall carpet installed puts a great deal of new textile product in your home, and there will be off gassing, that New Carpet Smell. The odor and off gassing from the new carpet is not toxic at all. You may wish to ventilate the area for a day or two, (air flowing over the new carpet and exchanged with fresh outside air). If the odor is still strong after the second day, go ahead and run the fan for a third day with greater exchange of fresh air. After three days the odor should have dissipated. If you still have a strong odor, then I would recommend looking for another source for the odor. Carpet can hold particles generated elsewhere in a house, especially one in construction or renovation. If you still think that there is a problem with your new carpet, please contact the store or your installers to confirm what products and installation methods were used. Any problem should be investigated and resolved to your satisfaction. The proverbial Las Vegas bookmaker would give odds that it is not your carpet.

Some specifics.

Reducing allergic reactions from the removal of old Carpet and old Pad.
Old carpet and especially old pad do hold an astounding number of dust mites and particles that can cause allergic reactions.

Shopping HINT: If you are affected by the air quality of a carpet showroom, you may wish to be elsewhere when your new carpet is installed. Most people can flip through stacks of new carpet samples for hours and not be bothered by the off gassing.


The Carpet Store.


How a carpet job is measured.

Sometimes customers shopping for carpet would bring in a rough diagram of their home's floor plan. This was helpful in guessing how a carpet could be laid down -- sometimes ruling out certain sizes of carpet or patterns in carpeting because of the resulting excessive waste, or seams in the worst places. However, I would order a carpet measure before ordering the carpet for a customer. A person who measures carpet jobs for a living will know what to ask (the customer) and look for to avoid ordering to little or to much carpet. Think of this as a tailor measuring a gentleman for a new suit. The tailor does not assume both arms will be the same length or the waistline will be in the usual place.

Most people do not measure their own carpet project. So, to save space on, (and load time of), this page, I have written a separate Carpet Measure Sub-Page. To view the page, just click Carpet Measure Sub-Page. A return button is included inside the page.

When someone is sent out to measure a carpet job, they like to know the type of carpet, the pattern repeat and width, (or choice of widths), of the proposed carpet.

For your convenience, I have added a sub-page that is a .GIF image of Graph Paper with one line of text for returning to this page. All you need do is click, PRINT, then return click.



WHAT TO EXPECT WITH A CARPET INSTALLATION

BEFORE THE CARPET ARRIVES.

THE BIG DAY.

Normaly, a carpet crew consists of two people, one installer and one assistant on the way to becoming an installer. [Mind you. I am referring to good crews, not warm bodies yanked off the street by unscrupulous carpet stores.] The crew may require access to electricity for their power tools. The crew will obviously need safe and ready access to the areas to be carpeted. Safe- meaning no dogs, cats or other pets and no small children under foot; appliances, lamps, etc. are to be unplugged: windows uncovered for sufficient light; good ventilation: and generally things that may interfere with the work should be dealt with or discussed with the crew before arrival. Ready access- meaning someone at the work site when the crew gets there, (or a key dropped off at the store a day ahead of time); no obstructions in the way of getting the 12' to 15' carpet goods as well as tools into the work area; security badges if applicable; access to where the old carpet and pad is to be placed for removal, (or reuse). [NOTE - If you wish to reuse the carpet, please make sure the crew knows this before arrival, or they may well cut up the old carpet into manageable strips customary for disposal]

THINGS A CARPET CREW WILL DO

THINGS A CARPET CREW WILL NORMALLY NOT DO.

AFTER INSTALLATION

Obviously, the first thing to do is examine the carpet and installation before placing your furnishings back into place. Specifically look for flaws in the carpet like streaks, crushed sections that cannot be brushed out, uneven pile hights not meant to be, uneven patterns or color intensity, etc. Also, look for mistakes and omissions with the installation. Is the carpet stretched, (it should not be loose enough to trip you when walked on)? Are the seems pattern matched? Do the seems show gaps? NOTE: It is not possible to completely hide seems from someone who knows where they are, but seems should be unnoticed to a casual observer. Are ALL the steps turned and tacked? Is a piece of the carpet not tucked under a baseboard? Are the transitions strips in place and in good shape? Generally, look for unfinished work.

Next, consider vacuuming the carpet, even if the crew already did. You now have a great deal of new textile product in your home, and there will be loose fibers. The off gassing from the new carpet is not toxic at all, but you may wish to ventilate the area for a day or two, (air flowing over the new carpet and exchanged with fresh outside air).

Now would be a good time to touch up the paint job as needed. Wallpapering can now be done. Please use drop clothes to protect the new carpet.

When you do place your furnishings into place, consider using glides under heavy pieces. Please remember to replace your window treatments before going to bed unless you like nosy neighbors looking in on your breakfast.

Try to save little scraps of the new carpet for color coordinating other things at a later date. Also, it is a good idea to save all the information about the carpet purchase for use later. Important information would include the invoice and warrantee information.



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