The Carpet Primer The Carpet and Rug Institute, Inc. www.carpet-rug.org PO Box 2048 706.278.3176 Dalton, GA 30722-2048 USA [email protected] Copyright © 2017 by The Carpet and Rug Institute, Inc. THE CARPET PRIMER Page 2 CONTENTS INTRODUCTION .................................................................................................................................. 6 CARPET CONSTRUCTION ................................................................................................................. 6 Pile Fibers and Yarns .......................................................................................................................... 6 1. Fiber/Yarn Types and Characteristics ...................................................................................... 7 2. Natural Fibers ........................................................................................................................... 7 3. Synthetic Fibers ........................................................................................................................ 8 Yarn Production .................................................................................................................................. 8 4. BCF Processing ........................................................................................................................ 8 5. Staple Yarn Processing ............................................................................................................. 8 6. The Heat-Setting Process ......................................................................................................... 9 7. Yarn Size .................................................................................................................................. 9 Coloration Techniques ........................................................................................................................ 9 8. Pre-Dyeing Methods ................................................................................................................. 9 8.1. Solution-Dyed Fibers .................................................................................................... 10 8.2. Yarn Dyeing .................................................................................................................. 10 8.2.1. Skein Dyeing ............................................................................................................. 10 8.2.2. Space Dyeing ............................................................................................................ 10 9. Post-Dyeing Methods ............................................................................................................. 10 9.1. Continuous Dyeing ....................................................................................................... 11 9.2. Beck Dyeing .................................................................................................................. 11 9.3. Printing .......................................................................................................................... 11 Carpet Fabric Construction ............................................................................................................... 12 10. Tufting ................................................................................................................................ 12 11. Weaving .............................................................................................................................. 13 12. Knitting ............................................................................................................................... 15 THE CARPET PRIMER Page 3 13. Needlepunching .................................................................................................................. 16 14. Bonding ............................................................................................................................... 16 Six-Foot Carpet and Carpet Tiles ...................................................................................................... 17 Entrance Mats .................................................................................................................................... 17 Area Rugs .......................................................................................................................................... 18 New Manufacturing Technology for Carpet Construction ................................................................ 18 Finishing Techniques ........................................................................................................................ 19 Protective Treatment ......................................................................................................................... 19 Backing Systems ............................................................................................................................... 19 Shearing ............................................................................................................................................. 21 CARPET SPECIFICATION ................................................................................................................. 22 Aesthetic Considerations ................................................................................................................... 23 Functional Considerations ................................................................................................................. 24 15. Carpet's Value in New Construction and Renovations ....................................................... 24 16. Thermal Insulation or Temperature Control ....................................................................... 24 17. Acoustics ............................................................................................................................. 25 18. Schools ................................................................................................................................ 25 19. Ergonomics ......................................................................................................................... 25 20. Safety .................................................................................................................................. 26 21. Maintenance–Less Costly ................................................................................................... 26 22. Specifications Case Study ................................................................................................... 26 Construction Specifications ............................................................................................................... 26 23. Important Factors ................................................................................................................ 27 23.1. Density .......................................................................................................................... 27 23.2. Pile Density Formulas ................................................................................................... 28 23.3. Gauge ............................................................................................................................ 28 24. Additional Factors............................................................................................................... 29 25. Summary ............................................................................................................................. 29 THE CARPET PRIMER Page 4 Performance Specifications ............................................................................................................... 30 26. Performance Specifications for Custom Orders ................................................................. 30 Specification Requirements or Inclusions ......................................................................................... 31 27. Installations ......................................................................................................................... 31 28. Specifying Testing Procedures and Criteria ....................................................................... 31 29. Government Specifications and Regulations ...................................................................... 32 29.1. Residential Carpet in FHA Market ............................................................................... 32 30. Flammability Requirements ................................................................................................ 32 30.1. Pill Test ......................................................................................................................... 32 30.2. Flooring Radiant Panel Test .......................................................................................... 33 31. The Americans with Disabilities Act .................................................................................. 33 32. Common Test Methods Used for Finished Commercial Carpet ......................................... 34 33. Specifying for Acoustics ..................................................................................................... 36 34. Specifying for Static Control .............................................................................................. 36 35. Specifying for Good Indoor Air Quality ............................................................................. 37 36. Understanding