Carpet and Flooring Construction Atlanta

 

CARPET CONSTRUCTION

How well a carpet floor will “perform” (e.g., stand up to regular wear and tear, including daily traffic, spills and pets) is determined primarily by:

• Fiber – The material used to make yarn (and how it is treated to fight stains);
• Construction – How the carpet is made (Twist, Gauge Rate, Density, etc.);
• Backing – The material through which the yarn is sewn; and
• Pad – The padding installed under a new carpet, which can make a big difference in the look, feel and wear of your carpet.

Carpet Fiber

The type of carpet fiber, along with the method by which the fiber is turned into yarn, significantly impacts both the price and performance of a carpet.

Carpet fiber is turned into yarn using one of two common methods: Staple or Bulk Continuous Filament (BCF).

Staple is a short strand of fiber (usually around 6 inches long) that is twisted together with other similar pieces of fiber to create a tuft of yarn. BCF is one long continuous strand of fiber that is used to create the yarn.

Because carpets made with staple fiber use many small pieces of fiber, they tend to shed, or “pill”, significantly more than carpets made with BCF. As more fiber comes off the carpet’s surface over time (through foot traffic, vacuuming, etc.), the carpet literally “wears” away.

Better quality carpets are typically made with BCF. The only benefit of staple fiber is its lower cost, which is why lesser quality carpets are often made with staple fibers.

Carpet fiber represents about 75% of the cost of making carpet, so it has a significant impact on carpet price. But the type of fiber also impacts how the carpet will perform in the home.

Most carpet floors today are manufactured from synthetic, or man-made, fibers, such as olefin, polyester or nylon. Each fiber has different performance characteristics affecting the look, feel and performance of the carpet.

Olefin (Polypropylene) is a relatively inexpensive synthetic fiber that is extremely resistant to stains and moisture.

Olefin is a solution-dyed fiber, which means the color is added during the production process rather than after the yarn is produced. The color is in the fiber through and through, not just on the surface. Think of solution-dyed fiber like a carrot: when you slice it, it’s orange all the way through. Fibers dyed through more traditional topical applications are like radishes: red on the outside, but white on the inside.

More importantly, the color is “locked-in” and only extreme heat will cause the dye sites to reopen. This makes olefin and other solution-dyed fibers “colorfast” (e.g. highly resistant to staining and fading).

While it is relatively inexpensive, there are some disadvantages to olefin:

Olefin is NOT “resilient”

• If you step on cut pile carpet made from olefin, it crushes and mattes (i.e., doesn’t return to its original position). This lack of “cellular memory” explains why cut pile carpets are NOT made from olefin.
• The natural shape of a loop pile carpet, however, creates added stability that makes up for any lack of “cellular memory” in the yarn. Consequently, loop carpets CAN be made from olefin.

Because it is solution-dyed, Olefin can NOT be made in bolder, vibrant colors.

• This is not generally an issue because customers tend to prefer neutral colored berbers.

Olefin tends to have an oily residue on its surface.

• When dirt comes into contact with olefin, it adheres to the yarn, accumulating over time and causing the carpet to appear soiled.

Olefin’s low cost, combined with its increased stability when made in “loop” form and its resistance to stains and fading, make it the fiber of choice for less expensive Berbers (as well as for the majority of commercial carpets).

Polyester is the most widely used fiber for residential carpets.

Polyester offers a number of benefits:

• More resilient than olefin (so it can be used to make cut pile carpet);
• Can be made in bright, rich colors (unlike olefin, which can only be made in lighter, more neutral colors);
• Available in specialized fibers offering increased softness;
• Highly resistant to staining and fading; and
• More affordable than nylon.

Polyester fiber is dyed after the yarn is extruded. Because of the chemical structure of polyester fiber, a tremendous amount of heat is required to open the dye sites. This characteristic makes polyester inherently resistant to fading and highly stain resistant, even to water-soluble stains (because, unless extreme heat is applied to the carpet fiber, the dye sites remain closed, blocking the staining agents from getting in).

Buyer’s Tip: There is a wide range of polyester fibers used to make carpet, from staple polyester to bulk continuous filament polyester made from virgin polyester to premium polyester made with advanced engineering to increase softness and durability. The differences impact both price AND performance. Make sure you know which polyester you are buying.

Nylon is the most expensive synthetic fiber. It is an incredibly soft, durable and resilient fiber. Combined with its ability to hide soil and stains, nylon is the ideal fiber for carpet used in the most highly trafficked areas.

The benefits of nylon can be summarized as follows:

• Softer to the touch than other synthetic fibers;
• More resilient than polyester and olefin, so it springs back under traffic;
• More resistant to wear and traffic, so it retains its original appearance longer;
• Treated to resist stains and soiling better than other fibers;
• Available in a wide array of colors and resists fading in sunlight; and
• More affordable than wool.

Special, branded nylon fibers have been developed, using state-of-the-art technology in chemistry and engineering to produce softer, yet more durable and stain resistant fibers. Branded fibers, such as Dupont’s STAINMASTER Tactesse Nylon, have the added benefit of quality assurance: they are manufactured to strict parameters and subjected to specialized testing.

Although nylon is not inherently stain resistant like polyester, nylon can be solution-dyed, a process that makes the fiber as stain resistant as polyester. And because nylon does not have an oily-residue, dirt does not adhere to nylon the way it adheres to olefin.

As described above, solution-dyed fibers cannot be made in bold, bright colors. However, there are nylon fibers which are NOT solution-dyed, such as STAINMASTER Tactesse Nylon. These nylons CAN be made in vibrant, bold colors. Since nylon is not naturally stain resistant, nylon fibers that are not solution-dyed must be treated with a topical stain treatment, such as STAINMASTER.

Buyer’s Tip: Not all stain treatments are equal. Lesser quality carpets use generic treatments that wear off after only a few cleanings. Even Scotch Guard, a recognized brand, wears off relatively quickly. It’s best to go with a carpet fiber that is inherently stain resistant or treated with a premium applicant, like STAINMASTER, which does not wear off.

Wool

Wool is the preeminent natural fiber used to make carpet, noted for its luxurious appearance, natural softness and high performance (e.g., natural resilience, good texture retention and good resistance to soil).

Wool is shorn from sheep and the natural shape of wool fiber keeps dust and dirt near the surface of the carpet pile, making it easier to clean. However, wool is not naturally stain resistant (although stain treatment can be applied).

On the downside, carpets made from wool are significantly more expensive than carpets made from synthetic fibers, which explains why wool carpets account for less than 1% of the total market.

Carpet Construction

In addition to the “type” of fiber used to make the yarn, carpet floor performance (or how well a carpet will wear and how long it will last) also depends on the manner in which the yarn is constructed.

Twist

Twist refers to how tightly the yarns in each tuft are twisted together. It is measured in terms of the number of twists per inch of yarn (TPI).

After the yarn is twisted, it goes through a heat setting process to lock in the twist, giving the yarn “memory” so that it retains its shape over time.

The twist level of a fiber significantly impacts how a carpet will stand up to wear. Generally speaking, the tighter the twist, the better the performance.

A tighter twist level will generally produce a carpet with more consistency in appearance and greater resistance to matting and traffic marks (because the yarn is more likely to bounce back to its original position after being walked on). A carpet with a low twist level will likely become unraveled with regular use and the ends will fray over time.

Some lesser expensive olefin berbers are made using a method called “Air Entanglement” (AE), rather than the standard method of twisting the yarn together. Air entanglement is a suitable method to make berber carpets because of the added stability created by tight loop construction. It is not suitable for cut pile carpet.

Buyer’s Tip: Some carpet dealers promote lower priced carpet that is made with high pile height but “low” twist, creating the appearance of a fuller yarn. Unfortunately, the yarn will unravel, or “flower”, over time.

Gauge & Stitch Rate

Gauge rate is the number of needles per inch used to “tuft” the carpet. It is a function of the sewing machine used to make the carpet. Stitch rate refers to the speed at which the carpet is fed through the sewing machine.

Pile Height

Pile height refers to the height of the tufts of yarn, measured from the backing to the top of the tufts. Generally, carpet with tall pile height is plusher, while carpet with low pile height is firmer.

Face Weight

Face weight refers to the “amount” of fiber in one square yard of carpet (ounces of fiber per sq. yd.). The “weight” of the yarn has a significant impact on both the cost and feel of the carpet, but not necessarily on the carpet’s performance. Density is a more critical measure of how a carpet will perform.

Density

Density refers to the thickness of the yarn and how close the tufts of yarn are spaced together (which is a factor of the gauge and stitch rate).

Carpets with higher density (i.e., the tufts are closer together) will generally perform better. You can measure density by pressing down on the carpet pile with one finger and seeing how easy or difficult it is to penetrate to the backing. Better, denser carpets are more difficult to penetrate.

Buyer’s Tip: Beware of lower priced carpets that feature relatively high weight in ounces but low density. As stated above, density is a more critical measure of how a carpet will perform. Carpets with high pile height and low density tend to matte and crush very easily, causing the carpet to wear very quickly (with the exception of Frieze, which has added stability due to high twist levels).

Carpet Backing

As stated above, yarn is stitched through a backing material to create “tufts”. The carpet backing holds the yarn in place, impacting the carpet’s durability, seam strength and overall appearance, including pattern straightness and the ability to keep its shape and not wrinkle.

Carpet backing is NOT all the same. Standard backing is made from woven polypropylene. Lower quality carpets use backing made from cheaper chemicals that make the backing tough and brittle. Over time, the backing loosens up, causing the carpet to sag and wrinkle.

Premium backing made from fiber offers many benefits over standard backing:

• Greater comfort under foot – Not only is the carpet itself more pliable, the backing is actually softer to the touch, making it more comfortable to walk on.
• Stronger and less visible seams – The carpet cuts very clean, making for cleaner seams that are less vulnerable to peaking.
• Improved dimensional stability to prevent wrinkling and buckling – Carpets with premium backing often come with “No Wrinkle” warranties.
• Improved cleanability – Premium backing keeps spills above the pad longer, so there is more time to clean up the spill.
• Softer and more flexible – Easier for installers to carry into the home and less likely to damage walls and baseboards during installation.

Buyer’s Tip: Beaulieu is the only major carpet manufacturer that uses premium backing made from fiber as the secondary backing. Other mills apply premium backing on top of the secondary backing (as stated above, typically made from woven polypropylene), which defeats the purpose of having premium backing – which is Beaulieu is the only company that offers a No Wrinkle warranty for carpets using its premium backing.

Carpet Pad

Carpet pad is as important as the carpet itself in terms of a carpet’s performance.
In addition, not using a pad, or using a pad that does not meet manufacturer specifications for the particular carpet, can void product warranties.

Carpet pad helps increase comfort and maintain the carpet’s original appearance by absorbing foot traffic. When you walk on carpet, you put pressure on it. Carpet pad helps to alleviate that pressure, which makes the carpet feel softer, thicker and richer.

Carpet pad improves the efficiency of vacuuming. A quality pad makes cleaning more efficient because it raises carpet off the sub-floor and provides air space underneath, allowing the carpet to “breathe.” When you vacuum, that space allows more air to come up through the carpet, picking up more dirt.

Selecting the “correct” pad (as specified by the manufacturer) helps minimize matting and crushing, as well as soiling and staining. A quality pad can increase the useful life of carpet as much as 50%. Pile crushing can make carpet “look” worn out before the fiber is actually worn out. A quality pad helps decrease pile crushing, allowing the carpet to maintain its pile height and stay looking new much longer.

The latest advancements in carpet pads are stain and odor fighting capabilities. A special moisture barrier on the surface of premium pads prevents spills or pet accidents from saturating the pad or soaking into the sub-floor, causing mold. This barrier gives the homeowner time to blot up the spill and prevent it from wicking back to the surface causing recurring stains.

Some premium pads have a special enzyme that helps eliminate offensive odors.

 

Pad Construction

Most carpet pad is made from foam or rubber, with foam pad accounting for approximately 75% of the market.

Bonded polyurethane, referred to as re-bond, is the most common form of foam pad. It is formed by combining chopped and shredded pieces of recycled foam, in different sizes and usually different colors, into one solid piece. The re-bond foam that is produced is itself recyclable.

Premium re-bond pad features:

• Heavier weight (typically 8 lbs vs. 6 lbs), compacted to make smaller air pockets, creating a denser, firmer pad that will perform better;
• Moisture barrier to prevent spills or pet accidents from saturating the pad; and
• Anti-microbial enzymes to help break down odors.

Product warranties typically specify the minimum type and grade of pad to be used with a specific carpet. The “grade” of pad is determined primarily by weight and thickness.

Note: A thinner pad is used for Berber carpets because a thicker, less dense pad would produce too much “give”, pulling on the seams.

Buyer’s Tip: Many contractors lower the cost of new carpet by reusing the existing pad or using a less expensive pad that does not meet manufacturer specifications for thickness and weight. In addition to causing wrinkling and buckling and separation of carpet seams, reusing the existing pad or using a non-specified pad will likely void the product warranty.