Carpet Construction Basics
Carpet Construction Basics
Did you know? Carpet construction influences carpet performance. By reviewing
carpet construction basics before buying carpet, the carpet you purchase will
maintain its appearance much longer.
Most residential carpet is manufactured using a process known as tufting. Tufting,
a process of inserting pile yarns into a backing material, accounts for more
than 90% of the carpet produced today. This process revolutionized the manufacture
of carpet by speeding production and making carpet more affordable for the masses.
Tufting is a process very similar to embroidery. Yarn is inserted into a backing
material to form the face material. In fact, tufting originated from the manufacture
of embroidered chenille bedspreads and was gradually transformed into rugs and
later broadloom carpet.
Once a tufted blanket has been stitched (yarns inserted into a primary backing
material), the blanket is back coated with a synthetic latex adhesive to lock
the fibers in place. A secondary backing is then applied to provide dimensional
stability. (See diagram).
Modern tufting involves Modern Tufting involves high-speed machines with numerous
“stitching” (tufting) needles lined side by side across the width
of the carpet. Visualize a sewing machine with 1400 needles. The distance between
these tufting needles, known as gauge rate, helps determine the density of the
face. Residential carpet is 3/16, and 3/8 gauge. Gauge is measured in needles
per inch across the width.
The following diagram describes the number of needles per inch for each gauge
rate and the number of tufts across the 12-foot width of carpet.
|
Gauge Rate |
Needles per inch |
Tufts across 12 ft width |
1/10 |
10 |
1440 |
1/8 |
8 |
1150 |
5/32 |
6.4 |
920 |
3/16 |
5.3 |
760 |
3/8 |
2.7 |
390 |
The number of tufts along the length of carpet is known as stitch rate. Stitch
rate, in combination with gauge rate and yarn pile height, is a primary factor
in determining product density and thus product performance. Stitch rate is
measured in stitches per inch along the length of the carpet. Stitch rate is
easily varied during manufacturing so stitch rate may vary more than gauge rate.
Gauge rate is limited by the preset positioning of the needles on a particular
machine; whereas stitch may be changed. In other words, an 1/8th-gauge machine
will always manufacture 1/8-gauge products, but may tuft a variety of stitch
rates. Ideally, stitch rate should represent a similar construction to gauge
rate. A 1/10- gauge fabric should have a stitch rate of around 10 stitches per
inch.
Pile height, the third component of carpet density, is measured from the surface
of the primary backing to the top of the tufted yarn. The higher the pile height,
the lower the anticipated performance. For example, an 1/8th-gauge product with
8 stitches per inch with a ¼- inch pile height will outperform an 1/8th-gauge
product with 8 stitches per inch with a ½ -inch pile height. In this
instance, the lower pile height provides a higher density construction and better
performance.
Twist level, is rarely examined by consumers or retail salespeople with regard
to performance, but twist level can have an enormous impact on performance.
Products with higher twist levels have the tendency to hold their original appearance
longer than lower twist products. Lower twist products tend to untwist or “blossom”
at the yarn tips creating a trafficked appearance. This characteristic provides
the “wet poodle” appearance associated with many residential constructions.
As the yarn tips untwist, they begin to intermingle with other yarn tips and
a matted appearance is displayed.
Twist level is measured in turns per inch. Many frieze products may have 7
to 9 turns per inch, while lesser quality saxonies may have only 3 to 4 turns
per inch.
Each of these three dimensions contributes to the anticipated performance of
the carpet selected. The higher the density of the construction, the better
the performance. Determining each of these factors is as easy as taking along
a ruler to measure each of the dimensions. Keep in mind that few products offer
the best of each of these factors. Each factor contributes to the cost of the
product as well. Also, a product of the finest quality that displays each of
these attributes has a much lower perceived value in the consumer’s eyes.
A densely constructed product with a high twist level may exceed your individual
budget and may not provide the softness, cushion, hand, or look that you desire.
Next >> Carpet Density
Article by Michael Hilton of carpetbuyershandbook.com - the Largest Online
Source for Unbiased Carpet Information (http://carpetbuyershandbook.com)
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