Carpet is sold in more areas and installed in more homes than any other type of flooring. Ranging from ultraluxurious to basic, carpet makes a home feel comfortable and complete. That's because carpet offers warmth, both visually and as insulation. While providing warmth and softness underfoot, it also absorbs sound better than any other flooring, reducing both surface noise and sound transfer between floors.
When choosing carpet, there seems to be an almost endless array of possibilities. Considering fiber choices, construction, styles, colors, design effects, and possible uses-not to mention prices that range from economical to extravagant-the word "endless" doesn't seem like a bad description of the options.
With so many choices, the task of selecting carpet for your home or business may seem daunting. Luckily, it's not. In fact, it's pretty easy to narrow your choices down if you take a little time to understand the benefits of the various choices available to you.
In this article, we will look at several variables including:
Fibers
Manufacturing processes
Tufted styles
Brands on nylon carpeting
Once you understand more about these topics, your choices will be much easier to narrow down, leaving you with the still daunting task of choosing a design or color.
FIBERS There are four main fibers used in carpet today:
Wool Wool has been used in carpets and rugs since ancient times, and is still considered the ultimate in luxury. It is the benchmark by which all other fibers are compared. It is strong, comfortable and prestigious. Nothing quite gives the look and feel of wool. It naturally repels water and has an ability to be dyed to just about any color. Wool used in carpet comes from New Zealand, Argentina and the United Kingdom to mention just a few. Natural wools vary in colors from off-white to black. The term "Berber," which is now considered a style or construction, originated from some of the natural blending used in wool fiber for carpeting. Wool cleans easily and ages gracefully. At carpetcapitol.com, you'll find some of the best wools from the world's best mills, including Expressive Design by Dalton and Godfrey Hirst out of Australia.
Nylon Nylon is the most frequently used fiber in carpeting today. Nylon was introduced in 1938 by Dupont and started our modern era of synthetic fibers. The use of nylon in carpeting has undergone several modifications before reaching the quality we have today. There are many manufacturers of nylon fiber for carpeting, and most of them have a premium brand of nylon. Given the heavy demand for nylon carpeting, we have listed the best nylon branded carpets near the end of this article.
Polypropylene or Olefin Fiber First introduced to the carpet industry in 1950, polypropylene is 100% solution-dyed, which makes it fade resistant. Usually found in continuous filament, it is great for outdoor use as well as indoor use. This fiber is not as resilient as nylon, but costs less for the manufacturer. Most constructions for this fiber are in loop pile or Berber loop pile which are more resistant to crush (carpet styles are described and shown below). If properly constructed, they offer exceptional value. Carpetcapitol.com offers many commercial loop pile products as well as many residential Berber loop pile products. We recommend you look at some of the Berber carpets in Olefin from Sutton, Queen, Philadelphia, Coronet by Beaulieu, Aladdin by Mohawk, and Cabin Crafts by Shaw.
Polyester First introduced to carpeting in the 1960s, polyester offers a little more tactile hand feel than nylon. Used in cut pile and textured constructions, polyester is most often used by the industry staple form. It is not quite as resilient as nylon but will give excellent performance if properly constructed. Look for well-twisted polyesters here. Gulistan Carpets makes an excellent product in polyester using their own "Twist Lock Technology". Because polyester is used in everything from soda bottles to fabrics, the fiber cost can vary greatly with market trends. From time to time, these fluctuations allow us to offer exceptional polyester values.
Staple vs. Continuous Filament All of these fibers come in either continuous filament or staple, except for wool (which is obviously not grown by sheep in a continuous filament). A well-built staple yarn, whether wool or synthetic, goes through blending, carding, pin drafting, spinning, twisting and heat setting. Continuous filament fibers are already in yarn form when they arrive at the mill and are twisted and heat set. The heat setting locks in the twist in the yarn bundle. A tighter twisted product will have less bulk but will hold its shape far longer. Frieze products are the highest-twist products. Twisted yarns are used in any cut yarn styles like textured or cut pile. Some yarns are air entangled rather than twisted. This process gives the yarn a more natural look, more hand, and more value. Air entangled yarns are usually found in Berber products and loop pile constructions.
MANUFACTURING PROCESSES There are two ways to make carpeting today.
Weaving Weaving has been used to make carpeting for centuries. Today, they are available as hand-made or machine made. Weaving takes longer, but results in a finished product that is extremely durable. The yarns are woven through or around vertical strands of fiber called warps. The yarns are then locked into place with horizontal strands called wefts. The carpet or rug may be hand knotted around the warps or woven around the warps. They come in a variety of patterns and allows for individual placement of colors in yarns for the finest quality looks and specialized designs. Most of our woven products use wool for the face fiber and are of the finest quality.
Tufting Approximately 90% of carpeting today is manufactured by tufting. While weaving attaches the fiber to fabric strands, tufting involves hooking the fabric by needle into a pre-existing fabric structure, usually by machines at high speeds. Four processes are included in the making of tufted carpets: processing the fiber, tufting, dyeing and finishing.
1. Processing. At this stage, many of the pattern effects, styling, and construction are created. The denser the construction, the better the performance. This stage determines the type of carpet style (frieze, Berber loop, cable, cut/uncut, etc.). The tufting machines of today use sophisticated computers to give the carpet just about any look imaginable. The carpets of today are better constructed and use a better fiber than in the past.
2. Dyeing: If the carpet is not using a solution-dyed fiber, it will need to be dyed using several different methods. This stage also gives the carpet color, pattern in color, multicolor, heather, and flecks as well as solids.
3. Finishing. The final stage in manufacturing is finishing, where the carpeting is sheered for the best finish (higher twist products finish the best here). The carpet also receives a secondary backing. Here the poly or action back is applied to give the carpet dimensional stability and allow it to be stretched over a pad. Some of our better quality carpets come with a high pic backing. This process is the same as that used in polypropylene construction but with a much tighter weave.
4. Stain treating. All carpets today are treated for stain protection. There are only a few of apartment grade products which do not come with stain protection.
Tufted Carpet Styles Use this chart for a look at and description of today's tufted carpet styles.
Frieze
Tightly twisted yarns in higher density. Frieze is the best performing style in a cut fiber construction for texture retention. This style is becoming very popular today, as customers are demanding performance. This style is now available in many different weights, solid colors, fleck colors and multi-tones. Considered casual or informal, it's a great style for high-traffic areas of the home.
Textured
Well-twisted yarns with a crimp give the pile a textured look. Carpets of this style can be used in moderate, medium or heavy traffic areas depending on the twist. Heavy traffic should use at least a 4.5 twist and be above 40 oz. in tufted face weight. Textured carpets offer a middle-of-the-road style that can be dressed up or down, with the homeowner's furnishings providing the design aesthetic for the room.
Cable
Cable carpets use well-twisted, heavier yarns that are usually tufted in a more casual construction. They are good for medium traffic areas, but there is a new cable yarn from Anso Crushresister TLC that will perform in heavier traffic areas. Offering cutting-edge style, cable carpets accentuate casual lifestyles where warmth and comfort are essential.
Cut / Uncut
These carpets are offered in both loop pile and cut pile. They can be styled with geometric patterns or a subtle scroll look. They are great where "traffic lanes" could potentially be worn in a carpet. More than the "old fashioned" look of the '60s carpets, today's versions of cut/uncut carpeting can be elegant.
Commercial Cut Pile
These commercial carpets are usually offered in solid colors with a little more formal look. Used primarily in upscale office and professional buildings, their use in residential applications is increasing due to their durability and wide range of colors.
Cut Pile Berber
These products are usually cut pile with a large yarn bundle. They have a fleck color system that helps hide wear, and offer a more comfortable look and feel to the Berber customer. For extra-heavy traffic, we offer the same looks in many brands using frieze twisted yarns. Look for the fleck colors in the frieze products.
Cut Pile Saxony
Similar to commercial cut pile or velvet cut pile, these carpets have a little more tuft definition and are not as smooth. They are not textured, but have some unevenness to the finish.
Sisal
Sisal carpets are usually twisted yarns in a loop pile construction. A style borrowed from authentic grass/woven sisals of native cultures, they are ordinarily tighter than a Berber and are offered in both nylon and olefin. The nylons in this category are better for heavier traffic and are available in both solid and fleck colorations. Sisals are becoming more popular every year. If you're looking for luxurious comfort or softness underfoot, this style may not be for you.
Velvet Cut Pile
This style offers a very fine finished cut pile with a small yarn bundle to create a formal, elegant style that can turn your room into a showplace. Its finish has almost a razor-shaved look that leaves signature footprints and vacuum marks.
Shag
A large yarn bundle with a longer tuft in a casual construction offers a return from decades past. Once again, though, it's considered a cutting-edge style. Use shag to turn a casual family room or den into a quiet retreat.
Commercial Level Loop Pile
Almost every commercial facility in America has at least some level loop pile carpet. Great for heavy commercial foot traffic, this style may also be a smart choice for bonus and play rooms.
Sophisticated Pattern
A unique look in the industry, these carpets are usually made from loops and cut piles of varying heights. More and more of these products are becoming available in popular patterns such as sculpted leaves, flowers and vines.
Berber Loop Pile
This distinction is given to any loop pile construction yarn in either nylon or olefin. Air entangled, they come in solids, heathers, multitones, flecks, and patterns. They're extremely popular right now, but shop carefully. They're not always as durable as some people think. The key to its durability is the density of the loops and the denier (diameter) of the fabric.
BRANDED NYLON CHOICES, A COMPARISON
Dupont
Stainmaster
This is Dupont's entry branded fiber. It provides superior resiliency, outstanding fade resistance, superior stain resistance, permanent anti-static control, and is protected by soil-resistant Dupont Teflon.
Stainmaster XtraLife
Same as Stainmaster except it is heavier and better built. This fiber is for heavier traffic in the home.
Stainmaster Grand Luxura
Same as Stainmaster except it is heavier and more luxurious. This is also designed for high traffic areas of the home.
Stainmaster Tactesse
Introduced in 2000, this fiber is extremely durable and yet feels more like soft cotton. Check out the newest styles in the Tuftex and Gulistan sections or browse Fiber/Stainmaster Tactesse.
Solutia
Wear Dated Freedom
Solutia's entry-level branded fiber. It is durable, stain resistant, soil resistant, and static treated. It is usually designed for no more than medium traffic in the home.
Wear-Dated II
Probably the most-used fiber in the industry for textured Saxony products. It is extremely durable, stain and soil resistant, and is permanently anti-static. This product has been in the market for years and is a true workhorse.
Honeywell
Anso Choice
Honeywell's entry-level branded fiber. It is durable, stain resistant, soil resistant and static treated. It is usually designed for medium traffic in the home.
Anso Crushresister III
One of the best values in the industry. It is extremely durable and stain resistant, and it is treated for soil protection. This fiber system locks in the twist and really lends itself to the Frieze styles in our industry. These styles will look the best for the longest.
Anso Crushresister TLC
The TLC stands for Twist Lock Control. This fiber is created for staple yarns and the process really locks in the yarn bundle. It has a little softer feel than the Crushresister III and looks good in Cut Berber styles, Cables, and Textured.
These are the main branded nylons in the market today. Branded yarns are good but make sure you also include construction and twist in your decision.
Performance Most manufacturers now offer performance test data on their products. For a true comparison on each styling, compare the twist, weight, and fiber. Remember, twist is your best friend here. It is the single most important factor in performance, especially in any cut construction products. You lose some hand, but your carpet will take the traffic better. Use a 4.5 twist for heavier traffic and go up from there for better performance and texture retention.
Pricing Information
