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The Carpet Primer

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The Carpet Primer THE CARPET PRIMER THE CARPET AND RUG INSTITUTE ISBN 0-89275-084-7 Copyright(c) 2003 update by the Carpet and Rug Institute. All rights reserved. Copyright(c) 2001 update by the Carpet and Rug Institute. All rights reserved. Copyright(c) 1997 update by the Carpet and Rug Institute. All rights reserved. Copyright(c) 1995 by the Carpet and Rug Institute. All rights reserved. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Printed in the United States of America. The Carpet and Rug Institute 310 Holiday Avenue P. O. Box 2048 Dalton, GA 30722-2048 Telephone: 800-882-8846 www.carpet-rug.com TABLE OF CONTENTS INTRODUCTION SECTION 1: CARPET CONSTRUCTION Figure 1.1 Typical Cut Pile Carpet Profile ......................................................................................1-1 Figure 1.2 Typical Loop Pile Carpet with Attached Cushion............................................... 1-1 Pile Fibers and Yarns....................................................................................................................................................... 1-2 Fiber/Yarn Types and Characteristics........................................................................................................ 1-2 Natural Fibers................................................................................................................................................. 1-3 Synthetic Fibers................................................................................................................................................ 1-3 Figure 1.3 Fiber/Yarn Production............................................................................................... 1-3 Yarn Production.............................................................................................................................................................. 1-4 BCF Processing.............................................................................................................................................. 1-4 Staple Yarn Processing.................................................................................................................................. 1-4 The Heat-Setting Process................................................................................................................................1-5 Yarn Size.......................................................................................................................................................... 1-5 Yarn Designation Systems and Methods of Computation........................................................................1-5 Coloration Techniques.................................................................................................................................................. 1-6 Pre-Dyeing Methods..................................................................................................................................... 1-6 Solution-Dyed Fibers.................................................................................................................... 1-6 Stock Dyeing.................................................................................................................................. 1-6 Yarn Dyeing.................................................................................................................................... 1-6 Skein Dyeing................................................................................................................... 1-6 Space Dyeing.................................................................................................................. 1-6 Knit-de-knit.................................................................................................... 1-7 Warp-sheet Printing..................................................................................... 1-7 Multicolor Skein Dyeing............................................................................. 1-7 Post-Dyeing Methods..................................................................................................................................... 1-7 Continuous Dyeing........................................................................................................................ 1-7 Beck Dyeing.................................................................................................................................... 1-8 Printing............................................................................................................................................. 1-8 Carpet Fabric Construction........................................................................................................................................ 1-9 Tufting............................................................................................................................................................... 1-9 Figure 1.4 The Tufting Process..................................................................................................... 1-9 Figure 1.5 Carpet Face Styles..................................................................................................... 1-10 Weaving........................................................................................................................................................... 1-11 Figure 1.6 Woven Carpet............................................................................................................. 1-11 Knitting............................................................................................................................................................ 1-11 Needlepunching.............................................................................................................................................. 1-12 Bonding............................................................................................................................................................. 1-12 Carpet Fabric Construction, Special Characteristics............................................................................ 1-13 Six-Foot Carpet and Modular Tiles............................................................................................................ 1-14 Entrance Mats................................................................................................................................................. 1-15 Area Rugs......................................................................................................................................................... 1-16 New Manufacturing Technology for Carpet Construction.....................................................................1-17 Finishing Techniques........................................................................................................................................................ 1-18 Protective Treatment...................................................................................................................................... 1-18 Backing Systems...............................................................................................................................................1-19 Backing Systems, Components and Typical Compounds.......................................................1-19 Moisture Barrier Backing Systems..............................................................................................1-20 Shearing............................................................................................................................................................ 1-21 SECTION 2: CARPET SPECIFICATION Aesthetic Considerations................................................................................................................................................2-1 Functional Considerations............................................................................................................................................ 2-2 Carpet's Value in New Construction and Renovations.............................................................................2-2 Thermal Insulation or Temperature Control...............................................................................................2-3 Figure 2.1 Thermal Resistance of Common Materials..................................................2-3 Acoustics......................................................................................................................................................... 2-3 Schools............................................................................................................................................................. 2-3 Ergonomics..................................................................................................................................................... 2-4 Safety................................................................................................................................................................. 2-4 Maintenance–Less Costly.............................................................................................................................. 2-4 Specifications Case Study............................................................................................................................... 2-4 Construction
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