Carpet Fiber and Construction

Carpet is one of the key decorating elements in a home and there are many styles and colors that are available. While style and color are important, more and more consumers are looking for carpets that have the ability to meet both the demands of time and wearability. Here are some factors on carpet construction and fiber to help in your carpet selection.

Fiber

Nylon – Nylon represents a high percentage of all pile fibers used in the United States. Although Nylon tends to be higher priced than most fibers, it has advantages that may make it more desirable depending on your application. Nylon has proven to withstand the rigors of an active lifestyle, provide brilliant color and can be cleaned readily.  Along with outstanding wear-resistance this fiber is the most resilient and is available in BCF (bulk continuous filament) and staple.

·      BCF (bulked continuous filament) - continuous strands of synthetic fiber that have been texturized to increase the bulk, coverage and resiliency of the fiber. The continuous strands allow the yarn tips to exhibit a very smooth, fine finish.

·      Staple fiber-short lengths of fiber, typically 4-71/2", that have been chopped from continuous filament and then twisted together to form spun yarns. The yarn tufts of staple products bloom more, exhibiting a “bigger hand” finish.

Olefin (polypropylene) – Olefin is a strong fiber that resists wear and permanent stains. It's notably colorfast and easily cleaned. Olefin is naturally resistant to static electricity and high UV, resisting fading in outdoor applications. All Olefin is BCF and is often used in commercial installations because of its inherent stain resistance.

Polyester – Polyester fiber is known as the soft “hand” fiber when used in thick, cut-pile textures due to the soft feel it offers. This fiber also offers excellent color clarity and retains its color and luster. Polyester is sometimes known by its chemical name Polyethylene Terephthalate or PET.  Polyester can be manufactured from virgin or recycled material such as plastic beverage bottles. While featuring many of the advantages of nylon, sales of polyester carpets have grown in recent years due to the value it offers the consumer.

Blends - Blends are when two or more various fibers are mixed together to create different carpet performance or different carpet styles offering good characteristics of each fiber. One common blend is an Olefin/Nylon.

Construction

All tufted carpet starts out in a loop construction. Visualize the carpet tufting machine as a large version of the sewing machine in your home; that is, if your sewing machine had hundreds of needles spanning from twelve to fifteen feet.

A strand of yarn comes off a spool and is tufted (sewed) onto a backing material. The yarn is threaded into a needle and penetrates the backing material on the way down and leaves a loop in the fiber as it returns. This loop can be left as is, or cut at the top to the loop to create two individual strands. All tufted carpets are either loop, cut pile, or some variation of the two. Many new styling directions have emerged as technology has evolved creating some of the most beautiful designs ever imagined.

Cut pile – Cut pile carpeting has cut loops on the surface leaving individual yarn tufts. Velvet, Plush, Saxony, Shag and Friezé (free-zay) are all cut pile carpets but differ in yarn twist. Cut pile carpets are still one of today's most popular carpet constructions.

Level loop – Level loop carpet consists of loops that are the same height and uncut, which creates a smooth level surface.  Arranging the loops closer together increases the durability and allows the carpet to be cleaned easier. Level loop carpeting generally lasts a long time in high-traffic areas and many of today’s popular Berber styles are created using level loop construction.

Multi-level loop – Multi-level loop usually has two to three different loop heights to create a pattern or sculptured looking effect to the carpet. Carpet with this texture tends to hide soiling and foot traffic.  Multi-level loop provides good durability with a more casual looking appearance.

Cut and loop - Combination of cut and looped yarns. This construction provides a variety of surface textures, including LCL (Level Cut Loop) sculptured effects of squares, pin-dot, swirls, etc.  It also tends to hide unwanted foot traffic.

Once your carpet selection has been made it is essential to realize that proper installation and adequate maintenance are equally important issues that must also be considered.

Carpet Cushion

Carpet cushion or padding is a critical flooring component. It provides the foundation for carpet and is responsible for enhancing both comfort and durability.

Padding is constructed of several different materials, including sponge rubber, foam rubber, urethane foam, bonded urethane and felted combinations of hair and jute.

Benefits of Carpet Cushion

• Quality carpet cushion can dramatically extend the life of a carpet by acting as a shock absorber whenever someone walks on the carpet. The cushion absorbs most of the downward impact caused by walking on the carpet and then springs the carpet's pile back up after each step.

• Carpet cushion adds comfort to any carpet and makes a carpet feel richer and more luxurious.

• A separate cushion installed underneath a carpet improves a carpet's acoustical and insulating properties making the room warmer and quieter.

• Cushion can also reduce fatigue caused by standing on a hard surface for extending periods of time.

• A separate cushion below carpet helps hide uneveness in a subfloor.

Always follow manufacturers' recommendations for cushion weight, density, and thickness, and make sure your dealer representative looks up the carpet warranty padding requirements for your carpet selection. It is important to note that the wrong padding can: 

• Cause wrinkling and buckling

• Trigger the carpet to separate from the backing or pull apart at the seams

• Break down the carpet

• Invalidate the warranty

The Green Alternative

American consumers use and discard millions of plastic soft drink containers every day. Some carpet manufacturers recycle these plastic containers into beautiful, luxurious carpet.

Because plastic beverage bottles are made with top quality PET (polyethylene terephthalate) resins as required by the US Food & Drug Administration, the recycled product is superior to lower grades of synthetic fibers used in making carpet yarns. PET bottles are sorted, ground into fine chips, and then cleaned. These chips are then melted and extruded into fiber and spun into carpet yarn.

Carpet Selection Tips

Choosing the right carpet involves a lot more than just finding a color to match paint or wallpaper. Here are some basic factors to consider before you select new carpet.  

Foot Traffic

Carpet is specifically engineered for high traffic areas, beauty, softness and appearance. Be sure to consider specific needs including location, children, and pets.

Stain and Soil Resistance

Most carpets offer stain resistance, but those who enjoy entertaining or have children and pets should consider carpets with high levels of stain resistance. Soil resistance is just as important as stain resistance for maintaining a beautiful carpet. Soil resistant products protect against soiling and staining by repelling dirt and spills from penetrating the fiber, making cleaning easier.

Anti-Static Protection

You may want to choose a carpet with permanent anti-static protection built into the fibers. This will create a more pleasant living environment during cold and dry seasons.

Carpet Type

Make the right choice by examining carpet construction.

• Texture: The textured surface of this carpet helps hide footprints and vacuum marks, and is the preferred style for busy households.

• Saxony: This luxuriously smooth, soft finish adds distinctive elegance to any room.

• Berber Loop-Pile: Berber’s subtle patterns fit a variety of room styles while hiding footprints and vacuum marks. Berber is the ideal choice for contemporary to cottage and country furnishings.

• Berber Cut-Pile: This carpet has the plush feel of thick, cut pile carpet. It is decoratively versatile, and ideal for casual rooms and kid’s rooms.

• Cut & Loop: Cut & Loop features carved definition, and accent colors spice up floor surfaces. The multicolor effects hide soil and stains while looking great between vacuuming.

• Commercial: This durable, long-wearing surface pile is engineered for high traffic areas and is perfect for professional and practical installations.

Color Selection

Carpet color and texture affect the character of any room. Rooms that lack sunlight can be brightened with yellows, apricots or warm beiges. Cool colors, like blues and greens, soften a room with a sunny exposure.

• Light colors show fewer footprints; dark colors show less stains and soil.

• Dull yarns show fewer footprints; while shiny yarns show more highlights and accents.

• Minimize maintenance by restricting light colors to less-used rooms.

• Multicolored carpets minimize the appearance of everyday stains and soil.

Fiber Selection

Fiber Performance in Carpet

 * assuming nylon is treated with a stain resistant chemical.
** assuming treatment with a soil resistant chemical.

Quality 

Durability is the measure of how long carpet will look and feel good. Ideally, carpet will retain its original texture and appearance for many years. Durability depends on finding the right balance of three important factors defined below: 

• Fiber: During carpet manufacturing, natural or synthetic fiber is converted to yarn and tufted, or locked into a backing to form the pile or surface that you walk on. There are five major types of carpet fiber - nylon 6,6, nylon 6, polypropylene (olefin), polyester, and wool; the most popular being nylon. Ideal for carpeting, nylon 6,6 is a man-made fiber that is wear-resistant (soil and stain resistant). Its natural properties allow for a very wide range of colors and color blends and the newest fibers offer the look and feel of wool, but with much less.

• Twist: The twist of the fiber is the way the fiber filaments are spun into yarn, and how the yarn is in turn twisted upon itself. Twist is usually locked into the fiber with a steam or heat-setting. The tighter the twist, the more the carpet will resist changes in appearance and texture.

• Density: Density describes the amount of pile in the carpet and how close the tufts are to one another. In general, the more dense the carpet the better the quality. Check density by pressing your fingers on the carpet and trying to reach the backing. It will be difficult to reach the backing of a very dense carpet. With the tufts facing outward, bend the carpet into a U shape to see how much of the carpet backing shows. The less backing you see, the more dense the carpet.

Samples

You want to take samples so you can see how the carpet will look in the space with it’s unique lighting and finishes.

Cushion

Selecting the right cushion can add years of wear to carpet. For residential installation, manufacturers recommend a cushion of no more than 7/16” thick and no less than ¼” thick with 6 pounds per cubic square foot of density, or equivalent. For berber (loop) styles, manufacturers recommend a cushion of 3/8 inch thickness with 8 pounds per cubic foot of density or equivalent.

Care & Cleaning

Proper maintenance of carpet will extend its lifespan and keep its fresh appearance. Carpet should be vacuumed regularly. Remove spills and provide long-term care and cleaning.

Floor Plan & Measurements

It is best to have your installer take measurements to ensure that you purchase the correct amount. As professionals, they know how to include hallways and closets, match patterns, plan seam placement, work with room irregularaties, and account for rooms with widths greater than 12 feet (most carpet is produced in 12- and 15-foot widths). Make sure that all cost estimates include padding, installation, seaming, stairs (if applicable), thresholds, the moving of furniture and the removal of old carpet or other flooring and materials.

Check out our handy Carpet Calculator if you need help measuring for estimation purposes.

Installation Details

Before new carpet is ordered, you will want to iron out the following details.

• Who is responsible for moving furniture in the room?

• Who removes and disposes of the old carpet and padding? 

• Are there any extra charges for these services? 

• Where will the carpet seams be placed?

Room Preparation

Be sure the room is prepared for the installation. 

• Carpet to be removed from the room should be vacuumed to avoid airborne dust or particles.

• Make sure the carpet installation is the last remodeling project for the room, after any painting, wallpapering or construction. 

• It is best if the roll of carpet is at normal room temperature when it is rolled out for installation. If it is being installed in a new house, and it is during winter months, the carpet should not be delivered prior to installation and left to sit in an unheated environment. If pre-delivery is unavoidable, then the heat in the house should be turned on to a normal temperature.

During Installation

• After the old carpet and padding are removed the floor should be vacuumed. 

•  Inspect the new carpet as it's unrolled for the proper color, texture and style. 

• Make sure the installers properly stretch the new carpet to minimize wrinkles and ripples. 

• If the new carpet prevents doors from opening, arrange to have them trimmed and rehung.

• Ventilate the room well - open doors, windows and run exhaust fans.

After Installation

• The new carpet should be vacuumed to remove the loose fibers.

• Ventilate the area for the first 48 to 72 hours, so the new carpet smell will disappear.