Posts Tagged ‘carpet defects’

Carpet Problems and Solutions: Carpet High Lines

Thursday, October 2nd, 2014

carpet high lines | Glenn Revere

Carpeting is made using one of two methods: tufting or weaving. Almost all of the residential carpet sold today is made by tufting. Tufting machines are basically giant sewing machines. Instead of a single needle, 800-1,000 computer controlled needles stitch carpet yarns across a backing material to form the carpet. The needles are set to control the height of the carpet pile. Sometimes a single needle stitches a row of yarn that is too long. Cut pile carpets are carefully sheared after tufting in order to assure a smooth, even pile surface. Even so, a high row or high line can show up after a carpet is installed. If the high row is bent over and buried in the carpet pile, the line may take days or weeks to appear after the carpet has been repeatedly vacuumed. Tufting high lines always run lengthwise. (more…)

Flooring Inspection Safari: Causes of Dirty Carpet

Tuesday, July 22nd, 2014

soapy carpet spot | carpet expert Glenn Revere

In a previous post, I discussed why a three-year-old carpet stayed clean after its first cleaning, but quickly soiled after its second cleaning. Sometimes, even a brand new carpet starts to “soil up” after just a few weeks. Here’s why.

Carpet mills have to add a detergent-based lubricant to any synthetic fiber (nylon, polyester, or olefin) when they spin it into carpet yarn. Otherwise, the heat from the spinning process could damage the fiber. This is called a spin finish. This lubricant is normally removed during the production process. But mistakes happen. Sometimes the spin finish stays in the carpet instead of getting removed. You can’t see it. When the new carpet is installed in your home, dirt starts to (more…)

Widthwise Lines in Carpet: Shift Marks

Thursday, June 5th, 2014

photo of carpet shift marks | Glenn Revere

Beautiful carpeting is made on very complicated machinery. When more parts make up a machine, more things can go wrong with the manufacturing process. The carpet mills know this. They have extensive inspection and quality control departments whose function is to find defective carpet and keep it from arriving at your home. In spite of these controls, mistakes happen.

Carpeting can contain various types of streaks, either lengthwise or widthwise in direction. There are many causes for these streaks. I recently looked at some carpet that had widthwise lines/streaks throughout the installation. The complaint for this newly installed carpet was listed as “uneven dye.” It was not noticed until the day after installation. I was asked by the mill to determine the cause of this problem. I arrived at my conclusion by using a process of elimination. (more…)

Common Carpet Defects: Carpet Pattern Bowing

Tuesday, May 20th, 2014

All kinds of lines appear in carpets. You can see some as soon as the carpet is rolled out; some don’t show up for several days or weeks. Some run lengthwise, others widthwise. Some can be removed, others can’t. Below is information on pattern bowing. I also suggest you read my previous posts on high lines and low lines in carpet, shear streaks, stop marks, shift marks and oil streaks.

Pattern bowing is only noticeable with printed or woven patterned carpet and loop patterned carpet. There are several causes for a crooked pattern, but the end result is that the pattern does not run straight when you look across or down the room. (more…)

Common Carpet Defects: Carpet Oil Streaks

Tuesday, May 13th, 2014

All kinds of lines appear in carpets. You can see some as soon as the carpet is rolled out; some don’t show up for several days or weeks. Some run lengthwise, others widthwise. Some can be removed, others can’t. Below is information on carpet oil streaks. I also suggest you read my previous posts on high lines and low lines in carpet, shear streaks, stop marks and shift marks.

Any mechanical equipment needs lubrication. Carpet tufters are complicated machines, with hundreds of moving parts that must be oiled. Machine oils from various places in the production line can get on the carpet pile. Part of the finishing process for broadloom carpets involves scouring and washing to remove contaminants. Still, because the oil is clear, (more…)

Flooring Inspection Safari: Latent Defects in Carpet

Thursday, May 8th, 2014

fuzzy carpet loops | Glenn Revere

Any manufactured product can have defects. Carpeting is no different. When carpeting comes off the final product line, it goes through an inspection process. The most glaring, obvious defects are caught during this mill inspection.

Once the carpet is delivered to your home for installation, your installer is the next line of defense against defects. It is the installer’s responsibility to examine the carpet for defects after it is unrolled. If he/she sees a problem, the installation is stopped until the nature of the defect is determined. Some defects can be corrected. Sometimes the carpet must be replaced. (more…)

Common Carpet Defects: Carpet Shift Marks

Tuesday, May 6th, 2014

All kinds of lines appear in carpets. You can see some as soon as the carpet is rolled out; some don’t show up for several days or weeks. Some run lengthwise, others widthwise. Some can be removed, others can’t. Below is information on carpet shift marks. Future blogs will cover other common line flaw types, such as oil streaks and pattern bowing. I also suggest you read my previous posts on high lines and low lines in carpet, shear streaks and stop marks.

Carpets are tufted with either straight rows or zig-zag rows. Zig-zag rows are made using a step-over stitch. When the tension of the tufting equipment is set too tightly, the carpet is made with too (more…)

Common Carpet Complaints: Side Match (Uneven Carpet Color)

Thursday, May 1st, 2014

side match | Glenn Revere

One of the more common complaints that carpet inspectors see is something called “side match”. This is a condition where the carpet color along a seam is darker on one side of the seam and lighter along the other side of the seam. There are several reasons why the color doesn’t “match” at a seam. The reasons are installation, manufacturing, or site related.

Today’s Inspection Safari involves a carpet installation in a Great room — a large, isolated room with a single seam near the center of the room. There is an obvious difference in color between the two pieces of carpet, one 13 feet wide and the other 8 feet wide, that are joined by the seam. The question is: what is causing this color difference?! (more…)

Common Carpet Defects: Carpet Stop Marks

Tuesday, April 29th, 2014

All kinds of lines appear in carpets. You can see some as soon as the carpet is rolled out; some don’t show up for several days or weeks. Some run lengthwise, others widthwise. Some can be removed, others can’t. Below is information on carpet stop marks. Future blogs will cover other common line flaw types, such as shift marks, oil streaks and pattern bowing. I also suggest you read my previous posts on high lines and low lines in carpet and shear streaks.

Carpet stop marks look like widthwise rows of missing yarn. (more…)

Common Carpet Defects: Carpet Shear Streaks

Thursday, April 24th, 2014

All kinds of lines appear in carpets. You can see some as soon as the carpet is rolled out; some don’t show up for several days or weeks. Some run lengthwise, others widthwise. Some can be removed, others can’t. Below is information on carpet shear streaks. Future blogs will cover other common line flaw types, such as stop marks, shift marks, oil streaks and pattern bowing. I also suggest you read my previous post on high lines and low lines in carpet.

You will see shear streaks when a tufting machine’s shearing blades malfunction. The blades can jump up when the machine stops or starts suddenly. Then you’ll see a (more…)