Floorcoverings

Delia Tacheny

INT 323 - Textiles, Materials, and Sourcing

Weekly Summary

This week we read chapters 20 and 21 about floorcoverings - another major textile product. The Carpet and Rug Institute (CRI) is a national trade association that represents the carpet and rug industry and offers a multitude of excellent resources. Carpets and rugs serve both functional and aesthetic purposes in a space. They create a sense of warmth and comfort and can add a level of durability to flooring surfaces. 

As always, the discussion of fiber is once again applicable and need not be deep dived as we have been discussing fibers and their properties since week 1. The top fiber choices for carpeting are nylon and olefin, particularly BCF (bulk continuous filament) nylon and olefin, which results in less pilling and fuzz than the staple fiber sizes. Backings are primarily made of olefin. Wool was once an extremely popular choice for floor coverings; it’s luxurious, durable, and fire-retardant. However, the shift in its consumption has been impacted by its increase in price and the improvements of synthetic fibers. The structural characteristics of soft floorcoverings are impacted by the yarn type and the pile yarn features such as height, density, and weight. Tufting is the #1 technique for construction and accounts for over 90 percent of the floorcovering market. In a tufted floorcovering there are three layers of the base: a primary backing, an adhesive, and then a secondary backing. The pile yarns are tufted throughout the primary backing and anchored to the adhesive. If a pile yarn is not securely anchored, the carpet could become unraveled, and the yarns could easily be pulled out when snagged; eventually there would be unflattering voids in the carpet. Piles can remain loops or be cut or a combination to form different textures.

There are a variety of options for floorcovering: wall-to-wall, carpet tiles, runners, area rugs, and scatter rugs. Each has their pros, cons, and distinct uses. Wall-to-wall carpeting is securely anchored, and can be installed on sub-flooring; however, it does require an installation cost and cannot be easily repaired or removed. Carpet tiles are a little more expensive up-front and can curl or separate, but they reduce the loss of material during installation, are easily rotated and replaced, can be lifted to access any under-floor service trenches, and offer design customization. Runners are great for narrow spaces such as hallways and stairs. Area rugs come in an endless variety of shapes, sizes, designs, colors, fibers, textures, and decorative detailing. Scatter rugs aren't very practical as they slide and are easily tripped over, but they are good for spots such as entry ways, bathrooms, etc.

Floorcoverings can be used to camouflage worn and uneven floors, add comfort, and even increase safety. Intentional design is absolutely necessary when designing for people with disabilities or visual impairment. A good carpet specification can improve the safety of disabled persons by producing a slip-resistant, smooth surface for wheelchairs to roll across with ease. However, designers must also consider the pile height and density as well as the position and installation of carpeting and rugs which can become a tripping hazard. It is best to specify a carpet with low pile height and high density, rather than a shaggy loose surface; and to consider adding a curb or beveled edge to allow a smooth transition between surfaces. Carpet and rug features can provide cues to the visually impaired about location, direction, and the overall environment. Changes in texture and surface can even help with orientation and circulation, as well as potentially provide auditory clues.

Research Initiative - BCF Nylon + Wool:

In general, carpet is typically constructed through the process of tufting, which I discussed in my recap of the reading above. Fiber yarns are looped through a backing material to form a row of loops which can either be cut or remain as loops; in general, this is considered to be the carpet pile (Lewitin).

Invented in 1935 and used originally in women's stockings, staple Nylon fibers were first produced for carpeting in the mid-1950's; and in 1959, Dupont introduced BCF (bulk continuous filament) (Simmons). Nylon is soft; durable; and resistant to stains, abrasion, mold, and mildew. It also absorbs and holds dye easily. Today, nylon is by far the most popular choice of carpeting (Lewitin). Part of nylon's resiliency is due to the hydrogen molecule that makes up part of its structure; steaming is the best method for cleaning nylon carpets because it revives the hydrogen molecule and can help flattened fibers bounce back (Simmons). The advantage of BCF nylon is that it will not shed nor become unraveled. While most staple fibers around 7.5 inches, BCF is a continuous strand. The only downside is that there are less design options for BCF fibers (Carpet Captain).

Wool is only produced in a staple fiber form which means it will shed. However, wool is the most popular natural fiber choice for carpeting as it is luxurious and soft. Wool is naturally resilient with good texture retention. Wool has great flame resistance as a natural fire retardant; good soil resistance; but poor stain resistance - it has high absorbency which also makes it prone to mold and mildew. One positive feature of wool's high absorbency is that wool carpet can serves as a natural humidifier - absorbing and releasing moisture in the air as needed. Wool is a fairly expensive choice but can be seen as a worthy investment for the right space and with proper upkeep (though it does require some high maintenance) (Simmons).

Whether you are going for a synthetic or natural carpet, Nylon and Wool are the cream of the crop in their category. As with any carpet, it's important to be aware of the necessary upkeep with either choice in order to preserve your investment. 

BCF vs Staple. Carpet Captain. (n.d.). https://www.carpetcaptain.com/carpet-buying-guide/bcf-vs-staple-fiber/

Lewitin, J. (2022, November 22). Understanding Carpet Fiber and Pile Cuts. The Spruce. https://www.thespruce.com/overview-of-carpet-choices-1315092#:~:text=Carpets%20are%20made%20by%20looping%20the%20fiber%20yarns,are%20treated%20is%20known%20as%20the%20carpet%20pile.

Simmons, C. (2020, July 27). All About Wool Carpet and Rug Fibers. The Spruce. https://www.thespruce.com/carpet-fibers-101-wool-2908802

Simmons, C. (2022, June 14). Pros and Cons of Nylon Carpet Fiber. The Spruce. https://www.thespruce.com/carpet-fibers-101-nylon-2908796