Understanding the Basics of Carpet Quality
Carpets that look similar quality may cost differing amounts and wear differently - find out the basics of carpet quality to become a better buyer.
tufted construction | materials | heat setting | tufting combinations | pile density | treatments | backing | useful links
Tufted construction
The vast majority of carpet bought by the public will be tufted. Tufted is made by inserting individual tufts through a primary backing and then gluing it to a secondary backing to add stability. The tufts are either (1) twisted and then sheared, (2) looped or (3) straight and sheared (velvet).
The yarn, the glue (or method of fixing), the backings and the methods of manufacture are the components to consider. The carpet salesman will know about some of these factors, but the industry is notoriously bad about making much of it clear - even to the company reps who sell it to the retailers.
Many of the basic manufacturing techniques may be executed with different levels of quality, for instance adhesive/latex penetration, yarn spinning, twisting and heatsetting. Poorly done and the carpet quality will be result in excess pile loss or shedding. Product reputation will be useful in ascertaining basic manufacturing quality - look for manufacturers rather than carpet sold anonymously such as part of wholesalers range.
Materials
Wool is the most expensive material, but wools differ according to where they're from. Sheep that have to struggle harder to live will produce the best wool - rather like grapes that struggle to grow make the best wines. British and New Zealand wools are considered to be the best and it can be no coincidence that both are in the extremities of their hemispheres for sheep population.
Man made materials like polypropylene and nylon are not going to be affected by geography but by raw material and manufacturing costs. Producers with the best production technology and the most advanced science will reflect those costs in their output.
With combination yarns such as 80% wool 20% man made fibre, you can expect nylon to be at a premium over polypropylene if it is the 20% man made part.
Heat setting or bonding
Whilst most carpet manufacturing methods will be based on the premise above, each stage can be subject to different manufacturing techniques. You will commonly find referal to heat setting or bonding. This is where polyesters are incorporated into the bonding processes by melting techniques.
Such techniques will add cost via the machinery investment necessary. Whilst bonding makes a considerable quality improvement, each manufacturer will brand their own techniques of bonding eg "meltbond" as if it is something superior. Branding processes are mostly for marketing pride and probably differ little from each other in the end carpet quality. (Manufacturers contact us if you wish to state anything differently).
Tufting combinations
This is where tufts are combined by wrapping individual yarns around each other. Most commonly it is two and is called two-ply or two-fold. This can be applied in the twist of tufts and in the making of loops. Three fold or more are occassionally found, mostly in loops. This process will cost more in the carpet production and hence in the price. It is proven to be a very important factor in increasing the resistance to wear of the carpet.
Pile density
Pile densities are measured by weight or gauge. Weights will be defined in imperial terms - the weight in ounces per square yard of carpet. Weights were commonly 32 - 40 oz in the seventies and eighties, but have now reached 50, 60 and 70 oz. Stairs and lounge wear should be at least 40 oz, with 50 now becoming the average. Sixty and 70 oz carpets are considered more of a luxury carpet quality.
Gauges refer to the amount of tufts per inch - 8 and 10th gauge being the most prevalent. As with ounces, the higher the gauge the more quality the carpet is considered and hence the greater life it has. This will be reflected in the price.
Treatments
Better quality carpets often come with inbuilt protection against moths, allergies and stains. Some treatments are applied by spray, but many are now actually manufactured in. This too will add to the cost and the life of the carpet. Be advised, carpet moths are an increasing problem so protection against them is a valuable addition to carpet quality (I have seen the faces of customers who've had to replace damaged carpets).
Backing
Backing cloths come principally in two types - natural hessian and man made Action Back (polypropylene). Some reps swear by hessian insisting it gives carpet quality more stabilty (less need for stretching) though I would like to see the evidence for this (again we would welcome any professional advice on this matter and will publish it here with the relevant credits).
Useful links
The Carpet and Rug Institute - detailed infomation on carpet construction
Westex - carpet featuring most of the techniques and materials in this articles
Patent for 2 ply yarn - if you want more information you can wade through this!
Glossary - carpet terms confirming much of this article
The Carpet & Rug Institute - further glossary of terms
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