CARPETS COMPOSITION- UNDERLAY/ BACKING -

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1 CARPETS Carpet is soft floor coverings. The quality of carpet depends not only on the method of manufacture, but also on how well the carpet is made, the fibres used, quality of fibre, and the density of pile. A good quality carpet should be able to withstand wear from constant footfalls, spillages, cigarette ash, and grit and also have the ability to recover from the effects of heavy or sharp furniture. Its shape and color should be stable even if deep-cleaned or constantly exposed to sunlight. The pile should be dense and made from strong fibres, held firmly in position. Carpets are used extensively in all types of establishments because of their appearance, the safety factor, warmth and sound insulation. Durability, appearance and ease of maintenance are the major concern when choosing carpet and floor. There are many carpets from which to choose, with a wide price range, and carpet performance may be judged by. Durability depends on- Resistance to wear. Resistance to abrasion. Good construction with tufts well held. Appearance depends on- Resistance to flattening. Soil and stain resistance. Color fastness to sunlight, water, shampoo, and rubbing. Safety depends on- Flame resistance. Comfort depends on- No build-up of static electricity. Length and softness of pile. COMPOSITION- Carpets primarily have three components- an underlay, a backing, and a face or pile. The pile is held to the backing with knots (in case of woven carpet) or with adhesive. As underlay is essential if a carpet is to be laid. UNDERLAY/ BACKING - Underlay or under-felt acts as shock absorber between the carpet backing and any un evenness in the sub-floor, which could cause pile to wear out. It tends the carpet to feel softer and more luxurious as well as helps to absorb pressure from furniture, provide increased sound and heat insulation. An underlay may also be attached beneath the carpet backing, when it is referred to as the secondary backing, or it may be installed separately. 1

2 BACKING The primary backing is the one in which pile of the carpet is anchored. It may be made of natural material such as jute, hemp or cotton, or synthetic material such as polypropylene, nylon, various resins, or synthetic rubber or of a combination of natural and synthetic materials. Normally the primary backing has bonding material that may be of rubber, latex, plastic, synthetic adhesive which holds the fibre in place. A secondary backing sometimes laminated to the primary backing provides additional stability; improve shape and resilience and more secure installation. These are not necessary for woven carpet. PILE Also called the face of the carpet, this is the part which is seen on the surface and walked on. Hence it should be strong and resilient. The pile may be made of a blend of fibres or exclusive synthetic or natural fibre (such as wool and cotton; silk is used in very expensive luxurious carpet). The blends used are typically of wool and rayon; wool and cotton; wool, acrylic and rayon; and so on. The synthetic fibres usually are polypropylene polyester and acrylic. The pile fibre density, height, twist, and the weave affect the carpet s resilience and durability. Different types of pile are- HARD TWIST PILE- This is a cut pile with heavy twist built into the yarn, giving it a pebble look. It is used mainly in plain carpets, but it can be combined with other types of pile to give a textured effect. Hard-twist pile does not show shading and tacking.(shading is the twisting of pile, caused by footfalls or the moving of heavy furniture, and shows up as dark patches. Tracking is the smoothing down of the carpet in heavily used area.) 2

3 LOOPED PILE The pile is uncut and is made up of a continuous series of loops. It can give various textures, from a thick and knobby pile to the closely curled low-loop pile that is like an irregular cord carpet. Looped pile is used in Wilton and Tufted carpets. CUT PILE- The loops of the pile are cut is such carpets. Tufted and woven carpets are produced in cut pile; Axminster carpets, it is the only type of pile produced. SHAG PILE- This can be produced on a tufting machine or on a Wilton or Axminster loom. The pile is long and shaggy and has luxurious look. TYPES AND CHARACTERISTIC- TYPES OF NON-WOVEN CARPETS- These carpets are produced by attaching the surface pile to a pre-fabricated backing. TUFTED CARPET- Tufted carpets account for about 95% of the total carpet production in the world. These are available plain or patterned and are usually made of synthetic fibre blended with wool. The tufts are needled into a backing- usually made of polypropylene in sheet form, but sometimes made of hessian. The tufts are locked into place with latex along the back. Then either the foam layer or a secondary backing of woven jute or polypropylene is added. If a foam backing is used an underlay is not required. The pile is either looped or cut. Tufted carpets do not fray. Shag pile carpets are usually singled-colored tufted carpets with a long, luxurious pile. The pile can, however, look tangled if it gets heavy wear. They are hard to maintain, too, since the long pile hides a lot of dust. BERBER CARPETS- These carpets have short, nubby tufts. The pile is dense and looped, characteristic made from natural, un-dyed sheep s wool. They are available in natural neutrals such as white, off-white, fawn, beige etc. 3

4 BONDED CARPETS- These carpets are neither woven nor tufted. The one feature that distinguished bonded carpets are that the materials used are glued, heat fused, or in some other way bonded together. They are all, therefore, typically manufactured from manmade fibres. A well bonded carpet is bonded and economical. BONDED PILE CARPET- These generally have a pile of nylon or polypropylene, which is stuck to a PVC backing. These are also available tile form. ELECTRO STATICALLY FLOCKED CARPETS- Bonding is also used for flocked carpet, which have thousands of small fibres electro statically bonded to an adhesive-coated backing. NEEDLE PUNCH CARPET- Another method of bonding is needle punch or needle loom. A mixture of fibres is punched by needles and entangled through a backing fabric. KNITTED CARPETS- These carpets are produced by interlacing yarns in a series of connected loops, as in woven carpets, the pile and the backing are produced simultaneously. Multiple sets of needles interlace the pile, backing, and stitching yarns together in one operation. TYPES OF WOVEN CARPET- Some of the highest quality carpets are made by the weaving method. The pile and the backing are woven together here so that the pile is locked into position. The weave consist of warp and weft yarns interwoven to form the face pile and backing at the same time. The pile may be cut or uncut. Woven carpets may be of three types Wilton, Axminster and Oriental. Wilton and Axminster are name of the loom on which these types of carpets are woven. The main difference is that the Axminster loom allows any 4

5 number of colors as the threads are cut off and reintroduced according to the pattern/design. WILTON CARPETS- Wilton is the most expensive weave used for carpet manufacturing. These may be produced as patterned, Cord, Brussels, or Plain. PATTERNED WILTON- these carpets are woven on a type of loom known as a jacquard loom. This is an apparatus that produces pattern from colored yarns. A perforated card contains the pattern/ design. These carpets give added warmth and resilience. Once the carpet is done the pile is cut and closed. No more than 5 colors are used. PLAIN WILTON These carpets are made without adding the jacquard apparatus to the loom. They have extra jute threads called stuffers added to the backing to compensate for the lack of the spare colored yarns as filling. CORD- These carpets are plain Wilton carpets with an uncut pile. BRUSSELS- these carpets are patterned Wilton carpets that have an uncut pile. AXMINSTER CARPETS- An Axminster-type power loom is capable of weaving high quality carpets with many varying colours and patterns. These carpets are woven is such a way that the pile is almost entirely on the surface. Each pile tuft is individually inserted into the backing, leaving no dead threads to reinforce it. The pile is less close and longer than in Wilton carpets. The backing is very durable. There are three types of Axminster carpet- SPOOL AXMINSTER- This is the most popular Axminster carpet and single piece can have an unlimited color in the pattern. The carpet is woven in such a manner that the pattern is visible on reverse side also. GRIPPER AXMINSTER- This carpet is similar to spool Axminster carpet, the only difference being the use of a maximum of eight colors, due to its method of creation. CHENILLE AXMINSTER- in French chenille means caterpillar. The threads the distinctly visible in the finished carpet, giving a segmented look like a caterpillar. These carpets are soft and thick and made in many colors and pattern. ORIENTAL CARPET- These hand woven carpets from the Middle East, Indian subcontinent and far East are available in a variety of sizes, pattern, and color. Based on the country of origin they are called Chinese, Indian, Afghan, Persian carpets and rugs. 5

6 Floral pattern dominate in India and Persia. Chinese carpets are easily recognized by pattern that includes dragon, monsters etc. a fine oriental carpet will have more than knots per square inch. SELECTION OF CARPET The responsibility of daily and periodic cleaning and maintenance lies on Executive Housekeeper. Once the types of carpet is decided on a specification sheet needs to be prepared for the dealer so that the right good id delivered. Selection criteria s are- SIZE- BODY OR STRIP CARPETING the narrow width of carpeting is known as body width, and this is either 27 or 36. This has no border so that the pattern can be matched when the strips are joined. BROADLOOM CARPETING- carpets are available in a width wider than body /strips width. The most common width are 9ft, 12ft, 15ft, and some as wide as 18ft. Tufted broadloom carpets are made in widths of 9ft 10.5inches or 13ft 10.5inches. These are best CARPET SQUARE These are loose carpet quadrangle with all edges neatened. The advantage of carpet square is that they can be turned to even out the wear. They are not exactly square. Sizes vary 6ft9inches X4ft or 9ftX12ft rectangular. CARPET TILES- These range from 9inches square to 20 inches square. A popular size is 12inches square. They are sold in packs of nine, which can be stuck down. Some have self adhesive that make it easy to lay. STAIR CARPET- these come in a width of 18inches and 22.5inches. they may be palin or patterned. RUGS AND MATS- these are normally oblong and should be less than 6ft9inchesX4ft. Rugs can be placed in areas of heavy use. PURPOSE They may broadly be classified in six categories- LIGHT DOMESTIC USE- Meant for bedrooms at home which are not walked upon much. LIGHT CONTRACT USE- at hotel bedrooms with less usage MEDIUM CONTRACT USE- may be used in hotel bedrooms and public areas GENERAL CONTRACT USE- these are for living room, halls, stairs, public areas and restaurants etc. HEAVY CONTRACT USE- mainly used in public areas or shops with heavy footfalls. LUXURY- these are better quality, not meant for general use- for eg. For hotel lobby good quality and hard wearing like Axminster made of 80%wool 6

7 and 20% nylon is suitable. For lounge- a plain Wilton or Tufted carpet is suitable. For dining areas- an acrylic pile carpet is practical as stains can be removed easily. For staircase- cord or needle felt is suitable as these are more hard wearing and incurs low cost. CONSTRUCTION- The surface pile and the type of backing are important selection criteria. PILE DENSITY AND WEIGHT- How well the carpet performs is mainly a matter of the density of the pile, pile with characteristic gauge, pitch, pile height, stitches, pile weight, and yarn size. Average pile density is the weight of pile yarn in a cubic yard of carpet. 36Xface weight Average pile density Pile height Yarn or face weight refers to the amount of fibre (per square yard) that is the face of carpet. Face weights normally range from ounces. I Carpet density ranges from Carpet density rating 2000 is considered average for mild usage. Twist Level The number of twists in a one inch strand of carpet is its twist level. Carpet with fewer twists can unravel. The number of twists is sometimes overlooked but is an important factor for carpet durability. Too low of twists may be very disappointing in an otherwise high quality carpet. On the other hand, a carpet with a high number of twists can compensate for a lower density. The shorter, the tighter the twist, the denser, the better the carpet. The short tight twist carpet is called a frieze. This is the best wearing style of carpet that is not a loop pile i.e. commercial carpet. A frieze with a longer pile and a little less density is a style called textured plush. This style is still excellent for wear, and has a elegant look. A textured plush with even less yarn creates a style called a textured Saxony. This style is still going to perform well, but in the very heavy traffic areas some crushing will be noticeable. Removing even more yarn, while keeping the same longer pile, will create a shag carpet. Shags are casual, and if tightly twisted using a nylon fiber, can give years of service. Shags will crush, but will recover with a good vacuuming. SHEARING OR FINISHING If the fiber is not crimped as in the above textures, and the carpet is sheared several times, the carpet will look like velvet in super dense construction, a plush in less dense construction, and a Saxony in even less dense construction. 7

8 Velvets are super formal and tend to show the most footprints, vacuum marks, and traffic. Velvets are also the most difficult carpets to seam well. If you have a desire for a super elegant carpet and do not mind footmarks etc. on the carpet, then you will love a velvet carpet. Plush carpets are very similar to velvets except for a slightly coarser look and a less dense pile. Also the twist in the fiber is not as tight as a velvet construction. Plush carpets are elegant and are often thick so as to feel good when felt by the hand or foot. Like velvet carpets, plush carpets show seams and footprints. Both velvets and plush usually come in solid colors. Solid colors are elegant, but do not hide soil. PILE HEIGHT AND STYLE- The length, thickness, and ply of the pile yarn affect the weight of the carpet and ultimately help in determining its wear. Pile height is the measurement (usually in fractions of an inch) of the pile of a carpet, from the base of the primary backing to the tip of yarn. Why does pile height matter? Pile height affects a rug in a number of important areas, including: durability, ease of cleaning and cushioning. Advantages of Shorter Pile (Less than 1/2 inch): Carpets and Rugs with shorter piles tend to last a bit longer and are considered more durable than rugs with longer piles. Along with this increased durability, a lower pile is less likely to catch an object and be pulled. Furthermore, a short pile rug can be vacuumed thoroughly. A shorter pile allows a vacuum to reach dirt at the very bottom of the rug without the risk of ruining it. Advantages of Longer Pile (Greater than 1/2 inch): Rugs with longer piles are considered more luxurious and soft on the feet. Although generally not as durable as rugs with a shorter pile, long pile rugs provide plusher cushioning and, with proper care, can still last for generations. PILE FIBRE Wool is dominant fibre for carpet pile. Wool is soft and resilient, resist abrasion and soiling, has natural flame retardant properties, feels warm; retain its appearance well if maintained properly. Though wool is expensive and suffers high static generation. Presently many manmade fibres, blends have become popular. The blends used are Wool and nylon- 80/20 Polypropylene and acrylic-50/50 RESILIENCE - It refers to the ability of the pile to recover its original appearance and thickness after being walked upon. In a guest room, warmth and comfort are important for the guests walking on bare feet or light slippers. DYEING- There are two classifications of dyeing residential carpets: pre-dyed yarns (dyed before tufting) and post dyed yarns (dyed after the tufting is stitched). There are numerous methods of pre-dye and post dye all can affect carpet performance and stain resistance. Additional types of dyeing include skein, stock dyeing, yarn dyeing, space 8

9 dyeing, extrusion dyeing, beck dyeing, continuous dyeing and print dyeing. If the colors must last for a longer period dope dyeing is ideal. Problems related to dyeing in carpets are crocking and bleeding. Crocking refers to the color rubbing off as a result of improper dye penetration. Bleeding is a loss of color when carpet is wet due to improper dyeing. AESTHETIC- This refers primarily to the color, texture, and pattern of the carpet. A spacious lobby should have larger bold pattern than those of smaller area. BACKINGa good carpets should have firm backing. The secondary backing gives the carpets dimensional stability, so that it resists stretching from foot traffic or from carts being pulled across it. Foam backing of 1/8 to ¼ inch thickness may be added to the primary backing to serve as a self cushion and to eliminate the need for separate padding. UNDERLAY/PADDING- If comfort and luxury is desired, one must choose a proper underlay. An ideal underlay, properly installed, with a quality carpet and good backing can prolong the carpet s life by softening the intensity of abrasion. Underlay also provides extra insulation against extremes of heat and cold, and acts as a acoustic-dampening layer. It is important to select a moth and mildew proof underlay. REPUTATION OF DEALER- The guarantee of quality and durability should range from 5-10years. It is preferred to that a reputed dealer, manufacturer and installer should be appointed for carpet selection and installation. INSTALLATION OF CARPET- Laying the Under pad When a carpet is not stuck down a carpet underlay made of felt, rubber or synthetic foam is essential in order to- 1. Eliminate any slight unevenness in the floor. 2. Retard crushing and creeping. 3. Provide an extra layer of heat and sound insulation. 4. Make the carpet feel soft and luxurious. 5. Take the strain of feet and lengthen the life of the carpet. 6. Rubber or synthetic underlay mat be fixed to some non-woven carpets. 7. The underlay should be of same size as the carpet. The installation methods are semi-permanent or temporary- LAYING OF CARPETS TOOLS Tackless strips Stapler Hammer Utility knife Chalk line Knee kicker Power stretcher Seam cutter Seaming iron Seam tape Wall trimmer Strip cutter Seam roller Knee pads 9

10 Measuring tape Rolling pin (or rental seam roller) Work gloves Safety glasses SEMI-PERMANENT METHODS- Stretch-in Carpets is stretched over a separate underlay onto narrow tackless strips pr grippers of wood with protruding tacks. The strips have two or three rows of nails, angled upwards to which carpets backing are attached during installation. Turn and tuck - the edges of the carpets is turned under like a hem and then tacked into position. Unless well fitted, this method can cause unevenness, which traps dust. Sunken- This method may be used where there is a change in floor level. The carpet is placed into the lower level of floor and fixed, hence the floor level becomes even. Glued down- this is more permanent method than the other methods. It is usually used with rubber or foam backed carpets. It may direct glue-down or double glue down. In the direct glue-down method, the carpet is adhered directly to the floor. In the double gluedown method, the underlay is adhered to the floor first, and then the carpet is glued to the underlay. The glue-down method is suitable- For most areas, including ramps and heavy-traffic areas. The seams are durable (but difficult to repair). Special design and border can be installed. There is no restriction on the size of the area to be carpeted. TEMPORARY METHOD- 10

11 These usually involve the addition of tape sewn round the edges of the carpet. This tape may contain pegs, hooks, press studs, or Velcro strips. Which attach themselves to corresponding sockets, loops, or hooks affixed to the floor surface beneath the carpet. CARE AND MAINTENANCE OF CARPETS- A regular maintenance programme is a must for carpets, since they are easily soiled or damaged. Good maintenance increases the life of carpet. Most new carpet shed fluff for the first few weeks. During this period carpets should be lightly brushed. After a month carpets should be vacuumed once a week. To even out wear furniture should be moved occasionally. Avoid dragging heavy furniture over carpet, as this damages the fibre. ROUTINE CARE- This involves daily removal of dust from the carpet. Dust is usually removed using drysuction vacuum cleaner or carpet sweeper. Care should be taken to clean the surrounding areas, corners and edges. Inspection is a regular duty of a housekeeper to ensure there is no pest infestation. PERIODIC MAINTENANCE- This involves deep cleaning of the carpet. Housekeeper should prepare a periodic schedule for this. When the dirt is visible deep cleaning should be done. Many properties carpet cleaning is contracted out because of the specialized equipment and skill required. Three different methods of deep cleaning are Shampooing carpet shampooing machine can use either liquid or dry foam. Shampoos are anionic synthetic detergent and should be used in correct dilution. Liquid shampoo very little foam. Dry-foam shampoos are actually also liquid, but they leave a dry foam on the surface of the carpet. Foam loosens the dirt holding the soil on the surface of the carpet which is removed through suction cleaners. Hot-water extraction This is done by a hot-water extraction machine. The machine uses a shampoo solution that does not form foam. It injects the solution under high pressure through the pile to the back of the carpet, where it emulsifies and loosens dirt and grease. Simultaneously, the machine sucks up the solution along with the now suspended dirt and grease. After the cleaning process, the carpet is left slightly damp and requires a very short drying time. Dry powdering- a powder containing absorbents such as sawdust, solvents and drying agents is sprinkled on the carpet and left for several minutes. The powder absorbs the grease and dirt, and it is removed with the help of a dry suction cleaner. This is usually used for spot removal from carpet. 11

12 CARPET PROBLEMS To keep carpet as attractive and clean as possible, housekeeping staff in charge of carpet cleaning should learn to recognize and remedy the following common carpet problems. Pile distortion Shading Fading Wicking Mildew Shedding/pilling PROBLEM CAUSE REMEDY Pile distortion 1. Heavy foot of Fibers can become twisted, equipment traffic. pilled, crushed or flared and 2. Improper cleaning matted methods Shading Dark and light areas appear. Fading Wicking Pile in the carpet is brushed in two different directions the dark and light areas appear. Natural aging, wear n tear, cleaning can combine to accelerate color loss. Premature fading may occur due to improper cleaning or spot removal. Occur when the backing of the carpets becomes wet and the face yarn draw or wick the moisture and color of the backing to the surface of the carpet. Occurs most frequently in jute backed carpet that has a light color face fiber. Mildew Forms when moisture allows molds in the carpets to grow. Causes staining, odor, and rotting May be impossible to remedy in hightraffic areas. Mats, runners, and furniture glides can help prevent crushing. Regular vacuuming or using a pile lifter or pile brush on hightraffic areas will help to pick up crushed pile while removing gritty soil, which can damage the carpets. Vacuuming or pile lifting the carpet in one direction can help but not eliminate it. Can be dyed. Always pretest carpet before using aggressive. Spot-removal techniques. Can be prevented by promptly attending to spills and by following proper cleaning procedure that avoid over wetting the carpet. Vinegar or synthetic citric acid solution used in post cleaning treatments or added to certain cleaning chemicals can help prevent or cure browning. All carpets should be kept dry and / or treated with an antibacterial to prevent the problem. Proper cleaning procedure that avoid Over-wetting that carpet can help prevent mildew from forming. 12

13 Glossary of Carpet Terms There are many technical terms used in the carpet industry. This glossary of carpet terms can help you navigate the jargon and learn more about the product choices. Adhesive A substance that dries to a film capable of holding materials together by surface attachment. Anchor Coat A latex or adhesive coating applied to the back of tufted carpet to lock the tufts and prevent them from being pulled out under normal circumstances. Antimicrobial A chemical treatment added to carpet to reduce the growth of common bacteria, fungi, yeast, mold and mildew. Antistatic A carpet s ability to dissipate an electrostatic charge before it reaches a level that a person can feel. Attached Cushion Adhering a cushioning material, (foam, rubber, urethane, PVC, etc.), to the back of carpet. Average Pile Density The weight of pile yarn in a cubic yard of carpet. It is calculated by multiplying the pile weight by 36, then dividing that product by the pile height (in inches). A calculation used primarily in the commercial carpet industry. Average Pile Yarn Weight Mass per unit area of the pile yarn including unexposed portions of the pile yarn. In the U.S., it is usually expressed as ounces per square yard. Axminster A type of carpet where the pile is inserted one row of tufts at a time, each row representing a section of the overall pattern. The tufts are Ushaped, and are anchored at the bottom into the primary backing that is simultaneously woven. The backing may have a synthetic starch or latex finish applied to it. Axminster weaving has been traditionally used mostly for creating multicolored patterned carpets. Backing (Primary and Secondary) Backing is fabric (in tufted carpet) that makes up the back of the carpet, as opposed to the carpet pile or face. In tufted carpet, Primary backing is the material that the yarn is stitched through. Secondary backing is added in the finishing process (after dyeing) and serves to add strength (dimensional stability) to the carpet, and insures the individual tufts are locked in place. In woven carpet, the backing is the combination of the construction yarns which are interwoven with the face yarn. 13

14 Back Seams Installation seams made with the carpet turned over or face down. Opposite of face seams made with the carpet face up. Both are on the back of the weaving or tufting operation. BCF See Bulked Continuous Filament. Berber A carpet constructed with coarse yarns having randomly spaced flecks of color against a background of base color. Currently, this term has expanded to describe many level or multi level loop carpet styles. Binding A band or strip sewn over a rug or carpet edge to protect, strengthen or decorate the edge. Bleeding-Transfer of fiber dyes from carpet or other fabrics by a liquid, usually water, with subsequent re-depositing on other fibers. Blend A mixture of two or more fibers or yarns. Breaking Strength The ability or capacity of a material to withstand the ultimate tensile load or force required for rupture. Broadloom A term used to denote carpet produced in widths wider than 54 inches. Broadloom is usually 12 feet wide. Burns Burns occur when the carpet yarn is exposed to an errant heat source and the fibers are melted or scorched. Burns should be addressed immediately. First, snip off the damaged fibers, then use a soap less cleaner and sponge with water. If the damage is extensive, see a professional about repairs. Cable A yarn made by twisting two or more plied yarns together. Typically a large, regular yarn. Carding In staple yarn manufacture, a process to remove impurities and short, unusable fibers. The fiber is cleaned and aligned to form a continuous untwisted string called a sliver. Carpet Any textile floor covering that is not designated as a Rug. Carpet Modules Carpet packaged as squares, generally 18 inches by 18 inches (457 x 457 mm), with or without attached cushion backing. Also referred to as carpet tiles. Colorfastness The measure of a carpet or yarn s resistance to fading. Cord A carpet where the pile has t been cut in lines, giving it a ribbed look. Crocking A term used to describe excess color rubbing off as the result of improper dye penetration, fixation or selection. Cross Section The shape of an individual filament or fiber when cut at right angles to its axis. Manufactured fibers used for carpet may have various shapes, including round, trilobal and pentalobal, as well as hollow varieties. 14

15 Custom Tufted Carpet or rugs in which pile yarns are manually tufted with hand machines or by narrow width tufting machines. Cut Pile A carpet fabric in which the face is composed of cut ends of pile yarn. Cut / Loop Pile A carpet fabric in which the face is composed of a combination of cut ends of pile yarns and loops. Dead Yarn The pile yarn in a Wilton carpet that remains hidden in the backing structure when not forming a pile tuft. Density Refers to the amount of pile yarn in the carpet and the closeness of the tufts. In general, the denser the pile, the better the performance. Density is often numerically referenced as the Average Pile Density (see that definition for a further explanation of the calculation). Direct Glue (Direct Glue Down) An installation method whereby the carpet is adhered directly to the floor. Double Back Woven or nonwoven fabric laminated to the back of carpet with latex or other adhesive. Double backed carpet has enhanced dimensional stability and strength. See Backing. Double Glue Down An installation method whereby the carpet cushion is adhered to the floor first, and the carpet is then glued to the cushion. Also referred to as Double Stick installation. Dry Foam Cleaning ( Dry Extraction Cleaning ) A cleaning process using a minimal amount of water, where a dense foam is worked into the carpet with a reel type brushing machine. The soil laden foam is then removed using a wet vacuum, which is often part of the same equipment as the brush. Dry Powder Cleaning ( Dry Extraction Cleaning ) A cleaning process using a minimal amount of water, where an absorbent solvent laced powder is worked into the carpet, allowed to set for a period of time, and then it and the absorbed soil and dirt are vacuumed up. Dry Rot A condition caused by attack of microorganisms on fibers, textiles, carpets or other materials, characterized by less strength and integrity. Attack on carpet backings permits carpet to break and tear easily. Natural materials, such as jute, are susceptible, whereas polypropylene and most other synthetics are resistant. Face Seams Sewn or cemented seams made without turning the carpet over or face down. They are used during installations when back seaming is impossible. Face Weight Refers to the amount of fiber (per square yard) that is in the face of the carpet (total weight less the weight of the backing). However, this is different than density because tall, less dense tufts may have the same face weight as short, 15

16 dense tufts. On average, short, dense tufts will be more resistant to wear and matting. Fading All carpet (like any textile product) is subject to color changes over time. This change is very gradual and is caused by oxidation through exposure to the open air within the home. Due to damaging ultraviolet rays, areas exposed to sunlight are subject to more dramatic color changes. We recommend that you take steps to protect these areas during high sunlight exposure hours by using draperies or other window coverings. It will help if a reputable company tints your windows if the window warranty allows, but tinting alone is not a substitute for window coverings. Felting Similar to fiber bonding, except in the yarn form or non woven fabric form, whereby the individual fibers are mechanically entangled (using a bank of needles) prior to the completion of the yarn manufacture. Fiber Natural or man made materials having very high aspect ratios. That is, having lengths hundreds to thousands of times greater than their widths. Useful textile fibers have high tensile strengths, flexibility, and resistance to heat, light, chemical, and abrasives. Any substance which can be made into yarn. Fiber Bonded (or Needlepunch) Carpet produced directly from individually colored (usually synthetic) fibers. The fibers are laid as a thick web and fed through a bank of barbed needles. This entangles the fibers (forming a felted surface), which are then impregnated with a chemical which, after drying, bonds the fibers permanently together. `Second generation products use an additional needling process to convert plain surfaces to ribs, velours and patterned textures. Chemical backings (such as high density foam and PVC) can be applied for use in suitable locations. Fiber Cushion Term used to describe separate carpet cushion made of needle - felted animal hair, jute, other fibers or fiber blends. Some are rubberized and may have one or two rubber surfaces. Filament A single continuous strand of natural or synthetic fiber. Filament Yarn A type of yarn whereby the individual fibers are much longer and tend not to be mixed, but rather bundled together before being twisted and heatset into yarn. Filler A low cost material used for extending rubber, plastic or other polymers. Fillers are generally powders of very small particle size. Carpet latex laminating compounds and foams contain large amounts of fillers. The most common filler in 16

17 carpet latex is finely powdered calcium carbonate, often called whiting, produced by grinding limestone. Filling Yarn In weaving, any yarn running across the width of the fabric perpendicular to the wrap yarns. In woven carpet, filling yarns are part of the group of construction yarns that also include chain and stuffer warp and form the backing. Woven carpet fill and chain warp yarns interface to secure the pile yarns. Filling and other construction yarns usually are cotton, polypropylene, jute, polyester, fiberglass or similar materials. Finishing A collective term denoting final processing of carpet and textiles subsequent to tufting, weaving and dyeing. Carpet finishing processes include application of soil retardant and antistatic chemicals, steaming, application of secondary backing, application of attached foam cushion, back beating, brushing, shearing and others. Flocked Carpet Carpet composed of short, chopped fiber or flock that is adhered, usually by electrostatic processes, to a base fabric, resulting in a short pile material with a velvety texture. Frieze (also known as Trackless or Textured) A frieze (pronounced fri ZAY ) is a cut pile carpet manufactured with yarn twisted so tightly it curls when cut. This curling can either be paired with a flowing, windswept look, or a dense, tightly packed construction to yield very differently beautiful looks. In either case, the tightly twisted yarn creates a casual, elegant finish that helps mask the appearance of footprints and vacuum tracks. It also provides outstanding durability for the active family. Fringe A decorative design element consisting of decorative edging and loose threads that is added to the edge (typically the ends) of a rug. Fabrica offers fringe as unknotted, single knot or double knot. Gauge In tufting, the distance between two needle points expressed in fractions of an inch (also see Gauge/Pitch). Gauge/Pitch The number of ends of surface yarn counting across the width of carpet. In woven carpet, pitch is the number of ends of yarn in 27 inches of width; e.g., 216 divided by 27 = eight ends per inch. In tufted carpet, gauge also means the number of ends of surface yarn per inch counting across the carpet; e.g., 1/8 gauge = eight ends per inch. To convert gauge to pitch, multiply ends per inch by 27; e.g., 1/10 gauge is equivalent to 270 pitch, or 10 ends per inch x 27. One eighth gauge is eight ends of yarn per inch x 27 = 216 pitch. 17

18 Heat Bonded A type of carpet construction whereby the face fibers are bonded to the primary backing, rather than being tufted through, or woven into, the backing. Jacquard An apparatus for a carpet weaving loom that produces patterns from colored yarns. The pattern information is contained on perforated cards. The holes in the cards activate the mechanism that selects the color to be raised to the pile surface. Wilton looms have jacquard pattern devices. Jute A natural bast fiber made from certain plants of the linden family, which grow in warm climates, such as those found in India and Bangladesh. Jute yarns are used for woven carpet construction (backing) yarns. Woven jute fabrics are used in tufted carpet as secondary backing. Knee Kicker A carpet installation tool used to make minor adjustments by stretching carpet (for installation with a tackless strip). By industry standards, the majority of this stretch must be performed using a power stretcher. Knitted Carpet Carpet produced in a fabric formation or process by interlacing yarns in a series of connected loops. As in weaving, pile and backing are produced simultaneously. Multiple sets of needles interlace pile, backing and stitching yarns in one operation. Latex A water based synthesis of synthetic rubber, natural rubber or other polymers. Latex is used to laminate secondary backing to primary backing in carpet manufacture. It is also used to adhere a rug backing as well. Level Cut / Loop (also known as Pattern Cut Pile) This type of carpet features a sophisticated look created by running cut pile and loop pile on a level pile height. The cuts and loops can appear random, or they can be arranged to create a distinct pattern. Level Loop This type of carpet features yarn on the face of the carpet which forms loops of basically the same height, with both ends laminated into the carpet backing. Loom Machine that produces woven fabrics. In weaving, lengthwise yarns (warp) are interlaced with weft yarns (fill) by the shuttle or other devices, such as gripper or rapier. Loop Pile Carpet style having a pile surface consisting of uncut loops. May be woven or tufted. In woven carpet it is called round wire. Luster Brightness, sheen, or reflectivity of fibers, yarns, or carpet. Synthetic fibers are produced in various luster classifications including bright, semi bright, semi dull and dull. Bright fibers usually are clear (have no white pigment), whereas the duller designations have small amounts of white pigments, such as titanium dioxide. Luster of finished carpet also depends upon yarn heat setting methods, dyeing and 18

19 finishing. In high traffic commercial areas, duller carpet is often preferred for soil - hiding ability. Markers Colored yarns woven into the backs of woven carpets to aid installers in achieving correct pattern match and pile direction. Multi Level Cut/Loop Pile This type of carpet features a sophisticated look created by running cut pile and loop pile, but the loops can be varying heights. The cuts and loops can appear random, or they can be arranged to create a distinct pattern. Multi Level Loop Pile Similar to a level loop, varying heights of carpet features yarn on the face of the carpet that forms loops, of varying heights. The various heights can be random, or they can be arranged to create a distinct pattern. Nap Another term for pile, usually used when discussing the pile direction, or the direction that the carpet came off the tufting machine. Needle 1. Tufting An eyed needle that inserts yarns into primary backing to form tufts. 2. Needle punching Barbed felting needles that entangle and compress fibrous fleeces into needled felts, such as those used for outdoor carpet. 3. Knitting Hooked needles that form the loops of knitted fabric. 4. Axminster Weave An eyed needle that delivers filling yarn across the loom through the wrap yarn shed. Nonwoven A fabric manufactured directly from fibers or filaments, or from a web of fibers without the yarn preparation needed for weaving, knitting or tufting. Nylon A synthetic fiber first discovered by DuPont (now Invista) chemists in 1938, but not used in carpet until much later. Today it is the most often used fiber for carpet (Fabrica uses it exclusively in our synthetic products) and can come in either filament or staple form. Features include cleanability, dyeability, stain and soil resistance, resistance to abrasion, ability to recover resiliency, moth proof, mildew proof, non allergenic and color retention. From the introduction of nylon for use in the manufacturing of carpet, producers have been continually improving the character of nylon fibers, making them more desirable and durable as a floor covering. Nylon has become the fiber of choice for high quality carpet. The manufacturing advancements mentioned above have been commonly referred to as generations within the carpet industry. The most recent generation is the fifth generation, boasting anti staining qualities as never before. 19

20 Olefin (or Polypropylene) A synthetic fiber used for some conventional, as well as indoor outdoor, carpets. This fiber is produced in continuous filament, fibrillated and staple form; solution dyed. Polypropylene is known for stain resistance, easy cleanability, wearability, and a low absorption factor. Other features include abrasion resistance, mildew proof, moth proof, non allergenic, resiliency, color retention and recoverability. Recommended for light traffic because it is less durable and less resilient than nylon. It also exhibits poor appearance retention and pattern walk out as compared with nylon. Oriental Rugs Hand-woven rugs made in the Middle East and the Orient. Over-tufting A manufacturing process whereby a previously tufted greige good is re tufted, usually adding a differing design element. Pile The visible surface of carpet, consisting of yarn tufts in loop and/or cut configuration. Sometimes called face or nap. Pile Crushing (carpet in use) Pile crush will occur to some degree. It is, in fact, unavoidable. It will be most noticeable in high traffic lanes and under the legs of heavy pieces of furniture. More frequent vacuuming will help minimize this condition in heavy traffic areas. Moving your furniture occasionally and using cups under the legs of furniture will also help minimize pile crushing. When it does occur, gently brush the area with your hand to hasten the recovery. Pile Direction This is the direction in which the pile naturally flows. This corresponds to the direction that the carpet came off the tufting machine. Pile Height A measurement (usually in fractions of an inch) of the pile of a carpet, from the base of the primary backing to the tip of the yarn. Pile Setting Carpet cleaning term for the process of erecting the damp and disheveled pile after shampooing by means of a pile brush or pile lifting machine. Plush (or Plush Finish) See Velvet Cut Pile. Ply This is a term used in describing how many single fibers are plied together to form a given yarn. At Fabrica, we often use multiple plied yarns (2 and 3 ply are the most common), because they offer enhanced performance and a beautiful look. Polyester A synthetic fiber introduced in some products in the 1950 s, and carpet in the 1960 s. It is made either as staple or continuous filament. Its characteristics include good abrasion resistance, good color retention, ability to accept bright, vivid colors, stain resistance, and wearability. It is moth proof, stain and soil resistant, mildew resistant and non allergenic. Recommended for light traffic because it is less durable and less resilient than nylon. It also exhibits poor appearance retention and pattern walk out as compared with nylon. 20

21 Polymers High molecular weight, chemical compounds formed by repeated linking of smaller chemical units called monomers. Polymers from which fibers are made are long chain molecules in which the monomers are linked end to end linearly. Synthetic polymers used for carpet fiber include nylon 6,6 and nylon 6 (polyamides), polyester, polypropylene and polyacrylonitrile (acrylics). In popular terminology, polymers are also called plastics or resins. Polypropylene See Olefin. Pre Installation Typically in rug manufacture (most often on staircases), this is when the broadloom component of a rug is installed before design components are added to it, so that the exact placement of those elements can be controlled. Puckering An installation problem when one side of the carpet is longer than the other side of the adjoining edge. The oversized carpet gathers in the form of wrinkles or pleats at the seam. Random Shearing A carpet texture created by running loop pile carpet through the carpet shearer whereby high loops are actually cut to become cut pile. Since cut pile is less reflective than loop pile, the resulting texture can actually appear to be different color. Also referred to as Tip Shearing. Resilience The ability of carpet pile to recover its original appearance and thickness after being subjected to compressive forces or crushing under traffic. Re stretch Repeating the stretching in procedure, subsequent to the initial installation. This can be required if improperly installed, if the carpet is too easily stretched, or if there has been too much moisture introduced into the carpet. Rubber A term sometimes applied to carpet cushion made from rubber (foam or sponge), and used for both separate and attached cushion. Rug A textile based product that is typically placed on the floor (rather than wall to - wall like carpet). Saxony A Saxony is a cut pile carpet with upright yarns in which the individual tips of yarn are clearly visible. For centuries, Saxony has been the classic cut pile construction. Scrim A reinforcing material glued to the seams in a rug to insure that they do not separate. Seaming Tape A tape, typically with an adhesive, used in the installation of carpet to bind two edges of carpet together. Seams In a carpet installation, the connection of the edges of two pieces of carpet using various seaming tapes, hand sewing or other techniques. 21

22 Shading After installation, carpet often appears to change color in certain areas. This phenomenon does not involve a true color change, but rather a difference in light reflection between various surface areas. Shading is not a manufacturing defect, but is actually considered to be the beauty of a cut pile carpet, simulating the look of velvet or suede. The condition occurs due to the difference in light reflection between the sides and tips of the yarn strands. As the pile surface is disturbed, the yarn sides will reflect more light than the tips, resulting in the highlighting feature so common in today s styles. Normally, this condition is temporary (such as with footprints). In rare cases, the condition is permanent. The latter is referred to as pooling or watermarking. The reason for this condition is unknown except that it is traffic related and random in nature. The pile fibers take on a permanent set based on the traffic patterns, and this set cannot be changed. Shag A carpet texture characterized by long pile tufts laid over in random directions in such a manner that the sides of the yarn form the traffic surface. Modern shags are made from plied, heat set yarns and are either cut pile or cut and loop styles. Shear In carpet manufacture, this is the process whereby a carpet is run flat through a machine that has large rollers with blades running around them. This action takes the pile down by minute fractions of an inch to present a uniform finish. Fabrica is known for its very refined finishes. This is attributable to (among other things) the quality and numbers of passes the carpet makes through this equipment. Shedding (or Fluffing or Fuzzing) This is a hairy effect on the carpet surface caused by loose fibers or slack yarn twist, whereby the fibers slip out of the yarn bundle, either in service or wet cleaning. Shedding is not a defect, but rather a characteristic of all new carpet, especially cut piles and wools. It is caused by short fibers within the pile that work loose during service. This condition is most evident in high traffic areas. Although your vacuum bag may fill with this surplus fiber, the total fiber loss during use is relatively small. Shedding will gradually decrease. The length of time required to eliminate shedding is dependent upon the type and amount of vacuuming performed. Sisal A product made of vegetable fibers such as coir, jute, paper and straw. It is susceptible to stains, mold and mildew, and has a harsh surface, providing no comfort under foot. 22

23 Skein Dyeing This is the process of dyeing carpet in the yarn stage, where the yarn is gathered onto individual skeins (yarn holders) and dyed. The yarn is then re - wound onto yarn cones or yarn beams, and carpet is then tufted as predyed carpet. Sliver An intermediate stage in the production of staple yarns, where the yarn is carded (cleaned and aligned in the same direction) into a sliver, and is then drafted (properly proportioned) before being twisted and heatset. Snags Sharp edged objects can grab or snag a carpet yarn (exposed nails in ladies high heels are a very common offender). If your carpet is snagged, simply cut off the snagged yarn with a pair of sharp scissors. Do not try to pull out these snags, as they are most likely attached to other yarns in the carpet itself, which can then be loosened as well. If the snag is especially large, contact a carpet professional for service. Soiling This is the build up of particles of soil and similar materials that cling to carpet fibers. Thorough vacuuming and proper routine cleaning (Fabrica recommends a dry extraction professional cleaning every 12 months) should minimize this problem. Improper cleaning can actually enhance the problem, as soap residue left behind from the cleaning attracts soil and increases the carpet fiber s propensity for soil adhesion. High quality carpet can aid in the prevention of visible soiling, as can darker colored carpet and stain protection added at manufacturing. Fabrica does not recommend the addition of soil or stain protection once the carpet is in service, and some after market additives can actually void your Fabrica and/or fiber producer s warranties. Please consult our Customer Service Department before adding any after market soil or stain protection. All Fabrica nylon products are treated to manage soil and stain. Soil Resist A chemical finish applied to the carpet fiber and/or surface that inhibits the propensity for soil to attach to the carpet. Stains Stains are spills of normal household substances that have either not been tended to in time, or are of a material that somehow over dyes the carpet. High quality carpet is dyed via the appropriate combination of water ph, temperature, and the presence of dye stuffs. Some household products (such as coffee) can actually work very effectively as a carpet dye. High quality carpet can aid in the prevention of visible stains, as can darker colored carpet and stain protection added at manufacturing. Fabrica does not recommend the addition of soil or stain protection once the carpet is in service, and some after market additives can actually void your Fabrica and/or fiber producer s warranties. 23