Carpet Fuzzing, Shedding and Pilling

Curious why the pile yarn on your carpet is fuzzy, has little balls on it, or the vacuum canister is filling up quickly? Are you worried that your carpet is defective or wearing out? Below I describe some of the methods that professional inspectors will use to make this determination. Follow these step by step instructions and determine if your carpet is fuzzing, shedding or pilling and what the cause of it is.

Is the Cut Pile Carpet Fuzzing of Shedding?

Rub your hand across the carpet in a brisk tempo to check for loose or attached fuzz. If fuzz develops do not jump to any conclusion as yet.

• Is the fuzz short and releasing or minimally attached? This type of fuzz is not unusual on cut pile constructions with spun yarn systems. Staple yarn filaments, which are cut during the tufting process and not bound at the backing by latex, are free to be pulled to the surface by traffic and abrasion. This type of surface fuzzing is known as shedding and it diminishes and becomes less noticeable with time. Shedding is a characteristic and not a defect.
• Check for long fiber that is not releasing. Grasp fibers between the thumb and forefinger and pull upward on them. If this results in a lot of long strands that are not releasing this is called fuzzing or bearding and may indicate inadequate latex saturation on the yarn bundle. If the latex penetration into and around the yarn bundled is inadequate the fuzzing is a manufacturer-related condition.
• Check the yarn bundle for latex penetration and encapsulation. Checking penetration and encapsulation requires some special knowledge so you may need to send a piece of the carpet to a laboratory. If you have both heavy fuzzing or bearding combined with inadequate latex saturation of the yarn bundle the problem is often manufacturing but many manufacturers will require that you send a scrap of carpet to them so they can perform there own test.
• Do you find some sprigs of fiber that are considerably longer than the other fibers in the yarn bundle? Using magnification, check some of the tufts that these long sprigs are coming from. Do you see fibers that are curled and tangled within the tuft shaft which, when straightened, extend well above the carpet surface? This problem appears to be directly related to the processing of the fiber. Again verification by a lab, manufacturer or both will be required as positive identification does take specialized knowledge.

Is the Fuzzing Being Caused by Poor Maintenance?

• Obtain and check a small sampling of the vacuum cleaner bag or canister contents. Determine the fiber length and debris content. Commonly you will find abrasive soil, short lengths of fiber, human and animal hair. The vacuum debris can tell you a lot about the soiling conditions the carpet is subject to.
• Check the carpet for excess soil or lack of maintenance. If you are not vacuuming regularly and deeply, have pets or gritty soil gets tracked into the house these all are hard on carpet.
• If you have an animal that is having accidents on the carpet or using cleaning chemical that leave residues on the pile you should be aware that urine and chemicals damage carpet. Beware that a qualified carpet inspector will usually find these concerns with ultraviolet light or other testing.

Type of Claim

• Consumer: Embedded dirt and grit is cutting fibers but leaving them still bound at one end.
• Manufacturer: Poor latex penetration and or encapsulation, which should be at least 75% - 80% on most cut-pile carpets. Need sample for testing the yarn bundle for latex penetration and encapsulation.
• Fiber: Poor yarn spinning, twisting or heatsetting. Need sample for testing.
• Normal Characteristic: If staple yarn and no consumer, manufacturer or fiber problem has been identified.

Correction of Fuzzing

Fuzzing can be removed by micro shearing. This will not be a permanent correction if maintenance problems continue or the carpet has poor saturation at the yarn bundle.

Why is the Loop Pile Carpet Fuzzing or Could it be Shedding?

Loop synthetic piled carpets rarely shed as most all of them are made with continuous filament yarn. In the rare situation that you are dealing with a spun synthetic yarn or a natural fiber such as wool you will find the same type of characteristics including shedding as described under cut pile carpets.

Fuzzing will appear on loop pile continuous filament products as a beard or fuzz on the surface. Poor or improper maintenance will cause it and so will inadequate latex encapsulation and penetration of the yarn bundle. At times you may find both poor maintenance and poor yarn bundle saturation. As with cut pile carpet a yarn bundle with poor saturation will allow fibers to slip and work its way to the surface with traffic and abrasion. Since the sprigs of filament are continuous and the synthetic fiber is strong it is difficult for them to break loose and this results in the fuzzy appearance.

Inspectors will often test a loop carpet with a “Velcro Roller.” This roller looks like a paint roller with Velcro on it. The test is most commonly performed by running the roller over carpet10 times in two different directions as they watch for the development of fuzz. Whenever possible this test should be made in a closet or on a scrap of the carpet for if your installed carpet fuzzes and it is not a covered claim you may have a fuzzy spot to live with. It should be noted that this test is very controversial and not recognized by some manufacturers.

• Check carpet for excessive soil or lack of maintenance.
• Check vacuum for samples of its contents, improper setting or damaged beater bar. If this is direct glue down carpet a rotating brush is usually okay but a beater bar can pound and damage the carpet.

Type of Claim

Manufacturer if poor latex encapsulation and penetration of the yarn bundle. 75% minimum level loop. 50% minimum heavy, loop piles such as bulky Berbers. Inadequate latex coverage will allow a continuous filament fiber to slip without release. A sample will usually be required for testing in the manufacturers own lab.

Consumer if the fuzzing is due to improper cleaning, abrasive soil or vacuum problems.

Glossary

Foreign Fiber or Foreign Matter:This is any material, which does not belong in the make-up of the floor covering such as dirt, soot or shear lint. When a carpet arrives from the manufacturer with foreign matter it is often correctable by vacuuming, picking out the debris or cleaning.

Fuzzing: (also referred to as bearding): A hairy effect on the carpet surface that develops when fibers work loose under foot traffic. Individual long filaments work free from the fiber bundle and began to extend above the pile surface and become visible as a taller sprig of fiber. These taller filaments are in fact bound in the backing system, which makes them difficult to remove. Fuzzing can occur on both staple and continuous filament yarn systems.

Pilling: A condition in certain fibers in which strands of the fiber separate and become knotted with other strands causing the appearance of little balls of fuzz or a rough appearance. Pilling on loop-pile wool carpet is less common than on synthetic carpets because wool fibers tend to break before the pill forms.

Shedding: New carpeting, especially cut pile, will shed little bits of fiber for a period of time. Eventually, these loose fibers are removed through vacuuming. With natural fiber and spun yarn (staple) the carpet may continue to shed some but to a lessor degree.

The Weinheimer Group LLC

Certified Inspectors / Consultants

Carpet for people with peeing pets

The pet dog or cat can become a very important part of a family. Many of us talk to them like they were our best friends. You regularly hear some one calling a dog by saying come to mommy or come to daddy. The loss of a pet is like loosing a member of the family.

On the downside, the best of pets can destroy a carpet. They get locked up in a room and have to relieve themselves and unable to open the door and go outside they do it on the carpet. Perhaps you have a new puppy! Sometimes a pet is getting old and starts to loose bladder control. Sometimes they just get sick.

In 1998 Solutia, introduced Wear-Dated Pet-Agree. While this product won’t stop the accidents it is a great help in cleaning them up. In 2008 Pet-Agree is still offering the product on selected carpets. Solutia’s Wear-Dated Pet-Agree has a protective backing which traps liquids to prevent nasty odors. The liquids are trapped on the surface where the pet owner can thoroughly clean up the accident. Since it is not soaking through the backing you no longer have the problem of the spot wicking back up from the backing. Liquid is not getting through to the subfloor therefore helps to eliminate permanent odors from urine getting into the floor.

Testing and Evaluating Wear on Carpet

Surface Appearance Changes in Pile Yarn Floor Covering

Wear Testing in the Laboratory

ASTM D5252

Hexapod Drum Tester is a 12″ diameter-rotating drum that new carpet specimens are placed in for testing. The samples are subjected to a metal ball with six attached polyurethane cleats or studs to simulate traffic.

ASTM D 5417

Vetterman Drum Tester is a 28.75″ diameter-rotating drum that carpet samples of similar pile height are placed into.  A 16-pound ball with polyurethane studs tumbles inside the drum to simulate traffic and wear.

ASTM D 6119

Foot Traffic

This method of testing creates surface appearance changes in carpet from foot traffic. Using a normal walking pace without scuffing, individuals walk across the specimens, which have been arranged in a particular walking path.  Foot traffic units are calculated either by photoelectric or hand held manual counting devices.

When carpet is tested in the laboratory for surface appearance change, 20,000 foot traffic units is the recommended standard for household applications.  ASTM D 6119 - 97 section 10.1

Section 1.2 states, “This practice is applicable to most changes in surface appearance observed in all types of carpet that are intended for residential or commercial use.  It eliminates change in appearance associated with soiling by focusing on appearance change due to matting, flattening, or change in pile fiber configuration.  Although “pile reversal” or “watermarking” is occasionally visible, this practice is not a reliable method for producing this phenomenon.”

During a controlled test the carpet is vacuumed every 1000 foot traffic units using a dual motor, top-loading, upright vacuum cleaner with a rotating brush.

Onsite Evaluation

When evaluating an actual installation onsite we are not dealing with controlled laboratory conditions.  Therefore it is important for us to obtain information that will help us to evaluate the conditions.

• Description of the area
• Number of individuals that reside in the residence or in a commercial situation the number of individuals that are normally in the area on a given day.
• Frequency of vacuuming
• Type and condition of vacuum
• Maintenance other than vacuuming

How rapidly will 20,000 units develop in a residence?

Now you can develop thousands of scenarios for an installation.  For this discussion I have developed two scenarios, a family of 4 and a retired couple (2)

Scenario One - A Family of Four

For this scenario, let us use a single-family residence and a family of 4.  Both parents work outside the home and the children are in school.  In the typical household there are days where the family or part of the family is away from the house for the entire day.  There are also days when the children or adults have company which increases the amount of traffic for that period of time.  Taking this information into consideration, for the sake of this discussion, 4 people are at this house 300 of the 365 days.

In the typical small house you will have cross traffic from the living room or a family room to the kitchen, service porch, bathrooms and bedrooms. 

Keeping foot traffic units to the very minimum for the sake of this discussion we come up with the following calculation for each family member.

Foot Traffic Units Family of 4

  3 trips to the kitchen from the living room

  3 trips back to the living room.

  3 trips to the bathroom from the living room

  3 trips back to the living room

  2 trips to the bedroom from the living room

  2 trips back to the living room

  1 trip when leaving the house in the morning.

  1 trip when returning to the house in the evening.

18 trip total per day per family member.  For the sake of this discussion we are not including trips to the laundry room, garage, or extra trips to any area.

Now to calculate the foot traffic units for this scenario.  18 trips x 4 family members x 300 days = 21,600 traffic units.  ASTM states 20,000-foot traffic units will produce a noticeable change. 

Scenario Two - A Retired Couple

This retired couple is at the residence most of the day, so the foot traffic units will naturally be different than for the family of 4.  For this discussion, lets say the retired couple is also there only 300 days per year.

Foot Traffic Units Retired Couple

  6 trips to the kitchen from the living room to get a drink of water of something to eat

  6 trips back to the living room.

  7 trips to the bathroom from the living room (no explanation needed)

  7 trips back to the living room

  3 trips to the bedroom from the living room

  3 trips back to the living room

  2 trips to go outside during the day.

  2 trips to back into the house during the day.

32 trip total per day per family member.  For the sake of this discussion we are not including trips to the laundry room, garage, or extra trips to any area.

Now to calculate the foot traffic units for this scenario.  36 trips x 2 family members x 300 days = 21,600 traffic units.  ASTM states 20,000-foot traffic units will produce a noticeable change.

While this is no way scientific, it is a reasonable consideration of use that points out how rapidly traffic change develops in an area.

ASTM Terminology

carpet, n-all textile floor coverings not designated as rugs.

change in surface appearance, n-for pile yarn floor coverings, the cumulative change in surface appearance between unexposed and exposed specimens due to crushing, loss of tuft definition, and matting.

crush, n-in pile yarn floor coverings, loss of tuft definition due to entanglement and compression of pile fibers.

floor covering, n-an essentially planar material, having a relatively small thickness in comparison to its lengths of yarn to the face of a primary backing.

foot traffic units, n-for pile floor coverings, the number of passes by human walkers over a specific group of carpet samples.”

Discussion-Foot traffic units should not be taken as the actual number of times each specimen is stepped on, but rather as the number of times that persons pass a designated spot on the walking course.

loss of tuft definition, n-for pile yarn floor coverings, the bursting, opening, and untwisting of pile yarn, decrimping of the fibers in the surface pile, or any combination of these.

matting, n-for pile yarn floor coverings, loss of tuft definition due to entanglement.

pile height, n-in determination of tuft height, a measurement that uses a small graduated ruler inserted until it touches the backing to measure the pile from the top surface of the primary backing to the top of the tufts.

DISCUSSION- Pile height is typically used generically by manufacturing personnel in setting machinery and by laymen.  This procedure is subject to significant variability between technicians and is therefore used only for rough fieldwork and machinery setting during the manufacturing process.

pile thickness, n-in pile yarn floor covering, the difference in the unextended height of the tuft elements above the backing measured as the difference between two parallel plates exerting a specified compression on the pile and backing and on the backing with the pile removed.

DISCUSSION-Pile thickness is the preferred procedure for precision measurement, and although it is more complex, it is very repeatable between different technicians in the laboratories.

pile yarn floor covering, n-a textile product in which yarn or yarn segments are attached intermittently to a backing fabric to project above the backing fabric and form a pile, in the form of cut loops or loops, or both, with the yarn entering the backing fabric substantially perpendicular to the plane of the backing fabric.

The Weinheimer Group LLC: Certified Carpet Inspectors, Flooring Consultants

Flooring Consultants

Improperly Specified Carpet

Carpet that is not properly specified will ugly out regardless of what it is installed over.  Most everyone has heard the statement “a good quality cushion will make an inexpensive carpet last longer.”  While there is a certain amount of truth to this statement, the best of cushion can only do so much for a poor quality carpet.  A carpet that is constructed with a loosely plied yarn and sparse in construction might do fine in a spare bedroom but it is not designed for the traffic of an active family.

Inexpensive plush is not going to hold up on stairs regardless of how good the cushion is.  By the same token, the finest piece of carpet is not going to hold up when installed over a cushion of improper thickness or density.

How Cushion - Carpet Pad Contributes to Ugly Out

Installing New Carpet over Old Cushion - Carpet Pad

It is common for an inspector to investigate an installation and find poor performing carpet installed over the old cushion.  While this old cushion may have looked pretty good to the installer or salesperson that talked them out of a new one, it has often lost much of its resilience. Was the salesman so unskilled that he or she was unable to explain the need for a proper cushion?  Was the installer just too lazy to take up and install a new cushion?  While the knowledgeable inspector might not know the motive for installing a new carpet over and old cushion, they certainly can tell when the cushion is bad.  When a cushion is bad they will report that fact in their findings.  A manufacturer may reduce coverage or refuse to warrant a carpet that is installed over an old pad.

Installing Carpet over Improperly Specified New Cushion

Just as with carpet installed over an old cushion, a carpet installed over a new improperly specified cushion will exhibit premature wear.  The Carpet and Rug Institute, Carpet Cushion Council, FHA, and most carpet manufacturers have recommended standards for carpet cushion.  Every individual that is selling carpet needs to know and follow these standards.  Just as with used cushion a manufacturer may reduce coverage or refuse to warrant a carpet that is installed over a cushion that does not meet their standards.  The Installer also needs to be aware of cushion standards for they are often blamed for restretching problems that are actually due to improperly specified carpet cushion.

The Ugly Out of Carpet

Every person in the floor covering industry and especially those that sell, install, inspect and service carpet need to understand the broad variety of complaints that they will face at any given time.  These same people need to understand that appearance and wear are not synonymous and in fact the two frequently used words are as different as apples and oranges.  Most consumers and far too many “experts” in the industry do not understand or refuse to understand the difference between appearance and wear.  As you read articles on this website the author is hoping that this difference will start to be understood. There is a saying in the carpet industry that has been around at least as long as nylon carpets.  “Carpet does not wear out it uglies out”.  Unfortunately, a knowledgeable inspector such as those from my own compant The Weinheimer Group LLC, often finds that a carpet has uglied out due to improper cushion selection, inappropriate maintenance or consumer ignorance or neglect.  When these types of problems are found it usually results in a declined claim a consumer and sometimes salesperson that feels they have been taken for a ride.  Educating the consumer at the time of purchase can usually prevent these problems.

Carpet Spot Removal Procedures

Procedures

1. Urgency is important with spot cleaning. The earlier that you get to it the better it will usually come off. Most carpet is stain-resistant but no carpet is stain-proof.

2. With a putty knife or the edge of other dull knife, scrape off as much of the foreign matter as you can.

3. Never scrub a carpet as this will distort and fray the pile. Absorb as much liquid as you can by blotting before adding any new liquid.

4. If you haven’t already done so, pretest your cleaning solution on a scrap of the carpet or in an inconspicuous area. Some products can damage carpet dye or cause yellowing.

5. Apply your spot-cleaning chemical to an absorbent towel. Never poor the chemical directly onto the carpet. Excess cleaner leaves a residue to attract soil. Some spotters in excess will damage the latex in the back of a carpet.

6. Work the spotter from the outside of the spot toward the center to keep the spot from growing.

Spot Removal Solutions

1. Detergent solution: To 1 cup of warm water add only 3 drops of dish washing liquid. Do not use laundry detergent or powdered dish washing detergent as these may damage the carpet. Do not add more then 3 drops of the liquid detergent, as excess will leave a residue that attracts soil.

2. Acetic acid solution: One half cup of white vinegar to one cup of water.

3. Alkaline solution: Two tablespoons of household ammonia to one cup of water.

4. Alcohol: Isopropyl or grain.

5. Dry cleaning solvent: Used for removing oily spots. Different brands are available for removing spots on clothing.

6. Rinse: Clear water

Removal Procedures Common Spills

Catsup: Scrape, blot, detergent solution, rinse, blot.

Coffee, Tea, Soft Drink: Blot, detergent solution, acetic acid solution, rinse, blot.

Feces: Scrape, detergent solution, ammonia solution, acetic acid, rinse, blot.

Ink: Blot, alcohol, blot, dry cleaning solvent, blot.

Lipstick: Dry cleaning solvent, blot.

Milk: Blot, detergent solution, rinse, blot.

Oil, Grease and Tar: Scrape solids, dry cleaning solvent, detergent solution, rinse, blot.

Paint, oil base: Scrape, dry solvent, detergent solution, rinse, blot.

Paint, water base: Scrape, detergent solution, rinse, blot.

Urine, fresh: Blot, detergent solution, rinse, blot.

Urine, dry: Detergent solution, ammonia solution, blot, acetic acid solution, rinse, blot.

Yellow areas dry and unknown: Rinse, acetic acid solution, blot.

Notice: All spots may not come out. All products should be protested on an inconspicuous area or remnant.

Static Electricity is it a Defect?

During periods of low humidity conditions, static electricity can be generated walking across a carpet or other surface. While the consumer will find this irritating it does not mean that the floor covering is defective. The generation of this condition can be significantly reduced or eliminated. This reduction can be accomplished by having a carpet treated with a anti static product approved for the carpet, of by increasing the humidity. Some of the ways to increase humidity are the use of a humidifier, pans of water placed in the areas where the condition is found or the use of indoor plants that require watering.__________________________________________
Basic Concepts in Electrostatic Discharge (ESD)
(Publicly Available Information)

Definition:
Static electricity is an electrical charge at rest. Static electricity is most commonly created by friction and separation. Friction causes heat which excites the molecular particles of the material. When two materials are then separated, a transfer of electrons from one material to the other may take place.

As electrons transfer, the absence or surplus of electrons creates an electrical field known as static electricity. The simple separation of two materials, as when tape is pulled off a roll, can also create this same transfer of electrons between materials, generating static electrical fields.

The amount of static electricity generated depends upon the materials subjected to friction or separation, the amount of friction or separation and the relative humidity of the environment. Common plastic generally will create the greatest static charge. Low humidity conditions such as those created when air is heated during the winter will also promote the generation of significant static electrical charges.

Materials that easily transfer electrons (or charge) between atoms are called conductors and are said to have “free” electrons. Some examples of conductors are metals, carbon and the human body’s sweat layer. Materials that do not easily transfer electrons are called insulators. Some well known insulators are common plastics, glass and air. Both conductors and insulators may become “charged” with static electricity. When a conductor is charged, the free electrons give it the ability to discharge rapidly when it comes close to another conductor with a different potential.

Typical Electrostatic Voltages:

Many of the common activities you perform daily may generate charges on your body that are potentially harmful to components.

Some of these activities include:

a) Walking across a carpet = 1,500 to 35,000 volts
b) Walking over untreated vinyl floor = 250 to 12,000 volts
c) Worker at a bench = 700 to 6,000 volts
d) Vinyl envelope used for work instructions = 600 to 7,000 volts
e) Picking up a common plastic bag from a bench = 1,200 to 20,000 volts

IMPORTANT NOTICE: This information was taken from a public service bulletin of Reade Advanced Materials and is for informal and general reference purposes only. Please contact the ESD Association or The National Fire Protection Association (NFPA) in Quincy, MA (telephone number: 1-617-770-3000) for confirmation of this information.

Carpet Terms

A

Abrasion Marks: Marks left on the pile of a carpet by abrasion.

Abrasive Wear: Commonly defined as the loss of face fiber through foot traffic. While wear is a frequent complaint, synthetic fibers are highly resistant to abrasion and most carpet will ugly out before it will wear out. (See ugly out)

Atmospheric soil/dirt: - As it relates to carpet, this is the dust, smoke, cooking vapors and other airborne contaminants that settle on the floor.

Axminster: Axminster \Ax”min*ster\, n., or Axminster carpet \Axminster carpet\ .

(a) [More fully chenille Axminster.] A variety of Turkey carpet, woven by machine or, when more than 27 inches wide, on a hand loom, and consisting of strips of worsted chenille so colored as to produce a pattern on a stout jute backing. It has a fine soft pile. So called from Axminster, England, where it was formerly (1755 — 1835) made.
(b) A similar but cheaper machine-made carpet, resembling moquette in construction and appearance, but finer and of better material.

B

Backing, Changes: A manufacturer may select to change the style of backing used on their product. A change of backing is not considered a defect as long as it is the same style of backing and of equal or better quality.

Bleeding - A change or transfer of color that occurs when the carpet dyes are exposed to water. Bleeding of carpet dye is not normal and can be caused by either manufacturing or non-manufacturing conditions.

Bow - An arc like distortion of a carpet pattern. This is a manufacturing condition that occurs when the speed of the tenter is running too fast, resulting in the carpet dragging on the inside rollers while the carpet is drying.

Buckling (Puckering) (Ripples)(Wrinkles) - Referred to by many names it is the ridge like areas that develop when a carpet loosens up. After a period of use a carpet may develop ridges and the condition will be due to one or more problems as follows. (1) The carpet was installed during cold weather and not properly conditioned prior to installation. (2) High humidity resulting in dampness between the carpet and floor. (3) Improperly specified cushion that is too thick or too soft. (4) Carpet installed over existing carpet. (5) Improper stretching of the carpet at the time of the originally installation. (6) Dimensional stability problem due to a latex condition, backing material condition, too soft or too stiff of a back or other that prevents the carpet from holding a stretch. Problems 1 through 5 can be corrected with a correctly performed power stretching and taking care of the additional underlying problem. Problem 6 may require replacement if it will not hold a restretching.

Burns - Most carpet will burn, melt or singe. Small burns such as those from a cigarette can often be improved by trimming the charred area with scissors. If the burned area is deep the trimming may be quite visible in which case it would be best to correct by reburling or an insertion of a small section of carpet.

C

Color Breakdown - Incorrect dyeing methods or defective dyes that result in a color change over a period of time. Not all manufacturers recognize color breakdown in the same way. Some do not consider it a defect when over a period of time. A sample of the subject carpet needs to be furnished to the manufacturer.

Color Change: It is normal for carpet to change color with use. Color retention is affected by the presence of sunlight, humidity, heat, oxides and other gasses in the environment. Color appearance changes in traffic areas from normal use and also as a result of improper maintenance.

Corn Rowing: Rows sometimes appear in certain styles of carpet and especially in high traffic areas. This condition can be caused by poor maintenance; pile crushing in traffic patterns or by repeated vacuuming in the same direction. Thorough deep vacuuming with a unit that has a beater bar, brushing cut bile carpet with a grooming tool, and routinely changing the direction the carpet is being vacuumed in will help to reduce corn rowing.

Cotton Count: This yarn numbering system is based on length and weight. The system was originally used for cotton yarn and later employed for most staple yarns. It is based on a unit length of 840 yards, and the count of the yarn is equal to the number of 840-yard skeins required to weigh one pound. Under the cotton count system, the higher the number, the finer the yarn. A typical yarn might be a three cotton count two plied, written as 3.0/2

Crocking: Dye rubs off of the carpet due to inadequate steaming during setting of the dye or not enough working time in the wash to remove all set dyes and chemicals.

Crushing: This is the compression or collapsing of pile yarns, under repeated foot traffic, so that the carpet mats down and loses all resilience. This form of carpet failure usually occurs in the areas of heaviest traffic.

Crushing, Furniture Indentation: These indentations develop under the weight of furniture legs. The dents can often be lifted with the edge of a coin. Stubborn indentations can be removed by steaming with a steam iron or travel steamer. When a back is very stiff or very soft, or the cushion under a carpet collapses you may not be able to remove the total indentation. Indentations are normally considered a characteristic and not a defect.

D E

Delamination: Is the separation of the primary and secondary backing and is due to a manufacturing, specification, installation or site-related cause. No claim for delamination at seams will be honored where lamination tests on the overall carpet meet accepted industry standards. No claims will be honored where improper padding has been utilized.

Dirty Back: Occurs when unwrapped carpet comes in contact with dirt or grime. This would not mean the carpet was defective.

Discolored or Stained Nap: This can happen when a wet carpet is put into dirty floats and wet yarn absorbs dirt of rust.

Dye Bands: Dye bands generally run lengthwise and can be cause by stops during continuous dyeing or by and uneven application of dye either too heavy or too light during continuous dyeing. (Also see rope marks.)

Dye Spots: These are randomly located spots that are caused by a heavier than normal concentration of dye of the same color or a different color.

Dye Streaks: Dye streaks generally run lengthwise and can be caused by uneven dye application, something rubbing on the carpet or from a crease that develops during the dyeing process. Clogged nozzle on dye equipment and not giving enough dispersion.

F G

Fading: Science has yet to develop a color that will not fade with time. All carpets will slowly lose some color due to natural and artificial forces in the environment. This can be delayed by (1) Frequently removing dirt by vacuuming. (2) Regularly changing air filters in heating and air conditioning systems. (3) Keeping humidity and temperature from getting too high. (4) Reducing sunlight exposure with window coverings or sunlight filter materials.

Filtration Soiling - Where air is forced through the carpet, under doors, along steps by air movement, soil will be deposited in streaks or spots. Professional cleaning may temporarily correct this, but the condition will reoccur until the airflow is corrected.

Footprints: Most deep cut pile carpet will show shoe or foot impressions. For those that find this objectionable, a carpet of lower pile and denser construction can help minimize this condition. Textured saxonies and frieze constructions are ideal for minimizing the appearance of footprints.

Fused Nap - Melted tips of tufts on nap that can be caused by excessive dryer heat.

Fuzzed fibers can be carefully clipped with scissors or sheared by a company providing correction services.

Fuzzing (Bearding): A hairy or beard like appearance on the carpet surface that develops when fibers work loose from the yarn bundle under foot traffic. It is frequently an indication of the need for increased vacuuming thoroughness or frequency. Fuzzing may be attributed to one or more of the following: (1) Embedded dirt and grit cutting the fibers but leaving them still bound at one end. (2) Poor latex penetration of the yarn bundle. (3) Poor spinning of the yarn. Poor twisting and heatsetting. (Also see shedding)

Grease on Nap: When this occurs during manufacturing it happens when the carpet comes in contact with bearings on equipment. Can be corrected by cleaning.

H I J K

Highlighting and Shading: Highlighting and shading are differences in light reflection between surface areas and are not defects.

Holes in Carpet: A carpet can burst in the dryer when it is stretched to tight or may be caused by forklift damage.

Hybrid Carpet: This is a carpet that is manufactured from more than one brand of fiber.

Indentations: These are marks left by furniture or other object. Shift location of furniture from time to time. Spray a small amount of water on the indented area and to lift, brush with a grooming tool available through carpet dealers or janitorial supply houses. For stubborn indentations hold a small travel steamer, holding it directly on the area or a steam iron several inches above the carpet surface, steam the dented area lightly and brush the tufts upward with your fingertips. Do not let the iron touch the carpet.

Insert: (Inset or cut and plug):

Installation Related Problems: installation related problems such as delamination at the seams, kicker damage, color change due to improper heating during seaming, tufts coming up, improper stretching or failure to use power stretcher, etc., are the responsibility of the installer or retailer/contractor.

L

Latex Lumps on Primary Backing: Small deposits of excessive latex forming lumps on the primary backing and hidden by the nap.

Latex on Nap: This is the result of the selvedge edge folding over onto the carpet face or a hole in the carpet that allows the latex to touch a face roller on the coater.

Light and Dark Edges: This is not repairable and occurs when the carpet shifts out from under the dye application causing the edge of the carpet not to be dyed or the selvedge can fold over during steaming which will cause dark edges.

Lint in Nap: Generally occurs during shearing when darker color ling falls on light color carpet or when lighter color lint falls of darker carpet.

Loose Secondary Back (Poor Lamination): Poor lamination of the secondary backing. Result of the carpet and/or the secondary backing failing to be hooked on the pins or the tenter chain of the Coater. This creates small areas of loose secondary backing which many times can be repaired.

M N O

Mating: This is the entanglement of fibers on the surface of a carpet pile. When the pile becomes compacted an actual loss of pile height may be caused. Common causes of matting are tip bloom, fiber slippage, sticky residues on the pile and soil.

Narrow Selvedge: The carpet was not hooked properly on the tenter pins of the dryer, which caused the unpinned selvedge to be narrower.

Odors: May be the result of bacterial growth or spills.

Off Shade: A carpet is off shade when the standard and the carpet do not match. This can happen through human error in color adjustment; or when carpet is stopped during the steaming process.

P Q

Pattern Match: Perfect pattern matches along seams may not be possible due to technological limitations in carpet finishing. Reasonable pattern match can be obtained when installed by a professional carpet layer, but is not guaranteed by the manufacturer and should not be guaranteed by the dealer or installer.

Picked Nap: This can happen when the carpet nap drags across a rough surface during drying.

Pile: The finished surface of the carpet composed of the yarn.

Pile Crushing: This is the compression or collapsing of pile yarns under repeated foot traffic, causing the carpet to mat down and lose all resilience. This form of carpet failure usually occurs in high traffic areas. Vacuum against the lay of the tufts with a beater bar style vacuum or brush with a pile groomer to lift and restore the crushed pile. (While a beater bar is advised for most carpets it can fuzz some Berbers and is not advised for carpets that are glued to the floor without a cushion.

Pilling: A condition where carpet face fibers from different tufts entangle with one another forming hard masses called “Pills”. This can occur in heavy traffic pivot areas, also with poor latex penetration. Pills can be safely clipped off with scissors.

Primary Backing: Primary backing materials are manufactured as both woven and non-woven fabrics in which the pile yarn is inserted by the tufting, needle punching, stitching, embedding or bonding. Primary back is the carrier fabric for the pile yarn and should not be confused with secondary backing which is a reinforcing fabric laminated to the back of tufted carpet subsequent to the tufting process. Some synthetic primary backings have nylon fiber attached to their upper surfaces to make them union dyeable with nylon pile yarns.

Pulled Mends: This can occur when drying level loop carpet and the rollers the carpet is running across pull the yarn.

R

Reburling: The replacement of damaged tufts by the insertion of new tufts.

Reverse Pile within the Roll: This can occur during the finishing process and is often correctable by steaming and reorientation of the pile.

Rippling - Ripples or wrinkles develop in a carpet due to a variety of reasons. Common reasons include 1) Cushion that is too thick or too soft. 2) Expansion and contraction of the carpets back due to changes in heat and humidity. 3) Carpet that has was not allowed to fully acclimate to its environment at the time of installation. 4) Carpet not properly powers stretched. 5) Carpet back that is very soft or very stiff. 6) Delamination

Roll Pile Crush: Some types of carpet may show a crushing of the pile when first installed due to the weight of the carpet roll depressing the pile during warehousing or shipping. Vacuuming will assist in roll pile crush recovery.

Rope Marks: This occurs when the carpet nap becomes folded over in the pad squeeze. Also, due to seams being sewn on a bias, which causes the carpet to fold over upon itself.
With beck dyeing it generally occurs with an uneven penetration of dye due to its roping condition in the dye beck. With beck dyeing it will usually run diagonally to the length of the carpet and is sometimes referred to as rope marks.

S

Seams: In any area larger than the width of the carpet and at most standard door openings, seams will be required. Seams will often be visible and invisible seams should never be guaranteed. Visibility of seams will vary with a carpet style and can be reduced by placing seams out of a major light source. In large areas, locating the seams so they run into the major light source instead of across it will help to hide the visibility.

Secondary Backing: Usually woven jute or woven or nonwoven olefin (polypropylene). The fabric is laminated to the back of carpet (usually with latex adhesive) to reinforce and increase dimensional stability, strength, stretch resistance, stiffness, and hand. Because secondary backing is visible, whereas primary backing is concealed under the pile yarn in finished carpet, dealers and installers often refer to secondary backing simply as “backing”.

Seconds and other merchandise sold “as is”
Shading/Vacuum Cleaner Marks: Shading is a normal characteristic of luxurious, dense, cut pile carpet. Shading typically becomes most apparent right after vacuuming. This visual effect is caused by the tips of the tufts reflecting light differently than the sides of the tufts. It is an aesthetic quality in the carpet design and not a defect.

Shearing Bad: Carpet is not evenly sheared.

Shearing: Finishing process in carpet manufacturing to create a smooth carpet face by shaving off fuzz. The shearing process can also be used to create texture as in random shearing. Carpet shears have many steel blades mounted on rotating cylinders.

Shedding: Fibers that release from the pile with foot traffic or vacuuming. Shedding is a normal characteristic associated with staple yarn (spun) cut pile carpets. It will diminish with a few months of routine vacuuming but will continue to shed to a smaller degree for the life of the carpet.

Side Shading: Edges of carpet compared to one another and found to be off in color and cast.

Slack Twist: Slack Twist: Refers to a yarn imperfection where insufficient twist is applied to the thread so it has very poor ply security.

Slight Dye of Texture Variations: It is normal for carpet to have dye or textural variations from original display samples or from dye lot to dye lot. Such variations are not a basis for a claim.

Slight Sidematch: Claims will not be considered for sidematch of the same dyelot if the variation is rated 4-5 or better based on the AATCC Gray Scale Rating. (The AATCC Gray Scale Rating is a nationally recognized comparison system to determine the extent of color differences). Where correction is required, manufacturer may employ on site color adjustment procedures.

Snags: If tufts are pulled out of the carpet, clip them off with scissors. Never pull them. If a long “run” (zipper) occurs in a looped or cut and looped carpet, a carpet repairperson can correct it by reburling or gluing it back in place.

Soft Back: Can be due to application of low levels of latex compound.

Soil or Stains Locally Caused: Stain resistance does not mean that carpet won’t soil. Locally caused staining or carpet soiling is not a defect in material or workmanship. Some staining may be covered by fiber manufacturer warranties and claims under their warranties should be made to them.

Soil Lines or Bands in Length or Width: Lubricants from equipment making contact with yarn. Improper application of finishing agents.

Soil/Dirt: Lighter color, pastel, light blue and light gray carpets show soil, spills, and tracked-in dirt more quickly than darker shades. Choosing a darker colored or patterned carpet can help to reduce the appearance of soiling. Keep your outdoor landscape friendly to your carpet to reduce tracked in soil and mud. Use doormats to help minimize tracked-in soil - and clean the mats frequently. Frequent vacuuming of the carpet at all entry areas is also important.

Sprouts: (Sprouting): Sprouts are loose tufts that protrude above the surface of the pile. On cut pile carpet some sprouts are normal and not considered a defect. Never pull on a sprout, particularly if it is a looped or cut and looped style as it may result in a row of pulled yarn. To remove sprouts clip even with the pile surface with scissors. Missing tufts are not considered as the basis for a claim. The manufacturer reserves the right to replace missing tufts.

Staining: Most of today’s carpets are manufactured with fibers that have inherent stain resist qualities or this feature has been added during the manufacturing. While stain resist makes it easier to remove most food and beverage spills it does not stop them from occurring. For cleaning follow the recommendations of the manufacturer. Most fiber manufacturers have toll free 800 or 888 numbers that you can call for stain removal assistance.

Static: A static charge can build up when the humidity is low, particularly when the temperature in the building is warmer than that on the outside. Humidifiers will help to control static. With use, a carpet will hold less of a charge. Carpets are available with built in anti static protection. Using a humidifier to add moisture to the air will help to control static.

Stiff back: Can be due to application of excessive levels of latex compound.

T

Tip Bloom: When new, the tuft ends of a “cut pile” carpet are uniform and evenly twisted. It is a normal characteristic for repeated foot traffic to cause some untwisting of the tufts. The higher the twist and the denser the pile, of the carpet the more resistant it is to tip bloom.

Tip Shearing: Shaving off tuft high loops in the finishing process to create a cut and uncut texture or pattern.

Tufted Carpet: Carpet formed by tufting.

Tufting: A carpet manufacturing process using needles to sew yarn into primary backing.

Tufts Pulling Out: Insufficient coverage of latex will allow tufts to pull out easily.

U V

Undyed Yarn: On solid colored carpets not enough dye was applied to completely saturate the carpet. When printing with print screens, the screen pattern can become clogged, not allowing the dye to pass through the holes in the screen.

Ugly Out: As it pertains to carpet, the loss of a carpets original appearance.

Vacuum Cleaner Marks: Shading is a normal characteristic of luxurious, dense, cut pile carpet. Shading typically becomes most apparent right after vacuuming. This visual effect is caused by the tips of the tufts reflecting light differently than the sides of the tufts. It is an aesthetic quality in the carpet design and not a defect.

W

Watermarking or Pooling: Watermarking or pooling is a color change effect which arises from the reversal or bending of the carpet pile fibers so that light is either absorbed or reflected from the pile. This is a common condition and is not related to carpet construction or fiber type and is not the basis for a claim.

Woven Backing: In tufted carpet, primary or secondary backing that has been manufactured by weaving. Jute and polypropylene are often used to produce woven secondary backings.

X Y Z

Carpet Cushion (pad) Terms

A

Additive - A material used to modify the properties, processing, or end use of a base polymer. The amount of additive used is usually expressed in parts per hundred (by weight) of the total resin n the polymer formulation.

Antioxidants - Materials which when added to a flexible polyurethane foam formulation improve the resistance of the foam to oxidative type reactions, such as scorch resulting from high exothermic temperatures.

Auxiliary Blowing Agent (ABA) - An additive used in the production of foam which supplements the primary blowing agent (water), and can be used to make foam softer or lighter. Compounds used to produce gases to expand, or blow, flexible polyurethane foam during production. Auxiliary blowing agents are low temperature boiling solvents, such as methylene chloride, acetone, hydrochlorofluorocarbons, and isopentane.

B

Ball Rebound -A test procedure (ASTM D3574) used to measure the surface resilience of flexible polyurethane foam. The test involves dropping a steel ball of known mass from a predetermined height onto a foam sample. The rebound height attained by the steel ball, expressed as a percentage of the original drop height, is the ball rebound resilience value.

Basal Cells - Larger, irregular cells found just under the surface skin of a molded foam part.

Board Foot - A unit of foam measurement equal to a square foot of material one-inch in thickness.

Bonded Urethane Foam (rebond) - Bonded foam cushions which are referred to as rebond are made by combining shredded or chopped pieces of scrap through a fusion process into a single sheet of material. Many grades of bonded cushion are considered to be among the best performing and highest quality carpet cushion products.

Bonding - Performed through adhesives or through a heat processes like flame lamination (also known as flame bonding) which bonds the foam to a fabric or other material (film, etc.) by melting one surface of the foam with a flame source and quickly pressing it to the other substrate before the melted material resolidifies.

Bottom Out - Lack of support under full weight load. This characteristic is often found in low-density foam. This term is very subjective, as a cushion may bottom out with a heavy person, and be very comfortable to a lighter-weight individual. Specifying a cushion with a higher density can reduce the problem.

Bun - A segment of foam cut off from continuously produced slabstock type of foam.

C

CFD (Compression Force Deflection) - A measure of the load bearing ability of a foam. It is the force exerted against a flat compression foot larger than the specimen to be tested. The value can be expressed at 25%, 40%, 50% and/or 65% compression (ASTM D3574). Note: Previously called “CLD (Compression Load Deflection

Colorant - Dyes or pigments added to impart color.

Conventional Prime - This is the basic prime cushion and represents the basic industry technology. It is much softer with many air-filled compartments with multiple open windows, which are formed by the surrounding network of elastic struts. This product will not perform as well as the better prime products.

Cushion Thickness - With cushion, thickness does not mean density. Thickness is the measurement of the product from one side to the other as the product has been manufacturer for use. Thickness is shown as a fraction or an inch or in its decimal equivalent, i.e., 5/32″, 7/16″, 1/2″, 9/16

D E

Densified Prime - This cushion provides a unique under foot feel. With densified prime the vertical compression is limited by the oriented cell thickness. The basic concept in densified prime is that vertical struts are stunted and the cell shape is flattened in directional orientation. The vertical compression is limited by the oriented cell thickness at a specified firmness. This is accomplished through controlling the foam rising action through mechanical or chemical technologies.

Density of Foam Style Cushions - A cushions density is equal to the weight of one cubic foot (12″ x 12″ x 12″) of foam.

Density of Foam Style Cushion Testing - To determine density a one cubic foot (12″ x 12″ x 12″) of foam is weighed. The weight of this cubic foot is reported as (x) pounds per cubic foot. This is a reasonably accurate test that is reporting the materials actual substance, in this case the substance being the density. The higher the density the better the support characteristics of the product.

Density per cubic feet - Total weight of material measuring one cubic foot, (12″ x 12″ x 12″) In theory, all cushion can be stated in density per cubic foot and in weight per square yard.

Discoloration - The gradual yellowing of foam due to a photochemical reaction. It is faster in sunlight than in artificial light, although it occurs in both. Fresh foam may discolor in the center of the block as a result of thermal or chemical events. Discoloration does not affect the physical properties of the foam.

Double Stick Cushions - A variety of cushions from sponge to needlebond synthetics have been produced for these installations. On double stick installations it is important that the carpet manufacturers specification for carpet cushion has been adhered to.

F

Felt Cushion (See fiber cushion)

Fiber Cushions (Felted) - Varieties of this type of cushion are produced from both natural and synthetic fibers. Natural fibers include animal hair, jute, hair & jute blends and rubberized hair and/or jute. Synthetic fibers include such as nylon, polypropylene and polyester. These cushions are most commonly used under commercial carpet and some berber carpet. They are made in widths up to 12′ and in weights from 32 to 85 ounces per square yard.

Frothing - A foaming technique in which air or other gases that are mechanically whipped into the polyurethane mixture using a high-shear mixer prior to the foam reaction.

G

Graft or Polymer Polyol - Polymers with active hydroxyl groups that have other organic groups or polymers “grafted” to the polyol molecule. These grafted organic compounds serve to reinforce the strength or modify other properties of the flexible polyurethane foam product

Grafted Prime - In this cushion part or all of the conventional polyol is substituted with a special polyol. This special polyol, referred to as a polymer polyol, graft polyol or copolymer, contains minute polymer particulate of styrene and other monomers which extends the harness range beyond that of conventional prime. With the exchange or addition of these reinforced polyols the hardness range of a grafted prime is extended far beyond that of the conventional prime products.

H

Hair Cushion (See fiber cushion)

Hard Spots - Resin - Spots that are hard like a marble are generally from the resin used in the bonding process. A spot that is hard enough to be felt is generally considered a defect. The proper correction is to remove the spot. A pad should not require replacement unless the spots are excessive.

Hard Spots - Skin - These are shiny, narrow hard pieces that come from the outside of some foam buns. An inexpensive pad will likely contain more skin than a better variety. Skin spots are a characteristic of many bonded urethane cushions and it is common for manufacturers not to consider them a defect unless they are large enough and hard enough to cause discomfort when walking in bare foot.

High Resilience (HR) Foam - This is a variety of polyurethane foam produced using a blend of polymer or graft polyols. High resilience foam has a less uniform (more random) cell structure different form conventional products. The different cell structure helps add support, comfort, and resilience or bounce. High resilience foams have a high support factor and greater surface resilience than conventional foams and are defined in ASTM D3770.

I J K L

IFD (Indentation Force Deflection) A measure of the load bearing capacity of flexible polyurethane foam. IFD is generally measured as the force (in pounds) required to compress a 50 square inch circular indentor foot into a four inch thick sample, typically 15 inches square or larger, to a stated percentage of the sample’s initial height. Common IFD values is generated at 25 and 65 percent of initial height. (ASTM D3574.) Note. Previously called “ILD (Indentation Load Deflection)”.

Isocyanate is a shorthand name for the family of diisocyanates, which are one of the two major ingredients in the chemical process by which polyurethane foam is made.

Jute Cushion (See fiber cushion)

Log Production Process - This involves developing the urethane in a cylinder shape referred to as a log. These polyurethane logs are peeled into the desired thickness, much like you peel plywood veneer from a log.

M N

Mechanically Frothed Urethane Foam - Frothed urethane foam cushions are made from a process originally developed to apply cushioned backings to carpet. Air bubbles are introduced by mechanically beating the chemical solution. The solution is solidified by heat and than fabricated into sheets of a predetermined thickness. A facing material is laminated to one side to provide stability and a surface for the carpet to be stretched across. Urethane foam cushioning is applied to a sheet of nonwoven material, forming a carpet cushion product with a typically higher density and firmer feel.

Mildew Problems - Slow seepage or flood that goes undetected or uncured for several days may result in mildew. Fiber pads suffer this problem. Rubber & foam are impervious, but they must still be removed because they retain water and the fact that carpet backings are also liable to suffer from mildew.

O

Oxidation Problems - Rubber & foam pads depend on the sealing off of floor & carpet surface to prevent undue oxidation. Areas with bad air pollution (NO2) (03) intensify problems. Fiber pads are impervious to this problem.

Ounces per square yard - Total weight of the ounces in on square yard (9 square feet).

P Q R

Peeling - The process whereby thin sheets of foam are cut from a cylinder of foam. Similar to plywood peeling.

Polymer - Organic substance composed of repeating chemical units built up into large molecules.

Polyol is a primary chemical in the formulation of foam. It is usually a glycerin-based product with three reactive hydroxyl groups. When mixed with diisocyanates and other specific ingredients, it produces the reaction that causes flexible polyurethane foam to form.

Polyurethane - Generally, a polymer connected by urethane groups. Urethane linkage and its supplements result from the reaction of polyol with isocyanate.

Prime Carpet Cushion - The carpet cushion industry denotes a group of cushion products that are made from slabstock polyurethane foam as prime. These products include conventional prime, grafted prime, and densified prime

S T U V

Scrim - A material attached to cushion so that carpet can be easily stretched across it.

Slab Stock - Flexible polyurethane foam that is made by continuous pouring of mixed liquids into a conveyer, creating a continuous loaf of foam.

Slabstock Production Process -This is a continuous process where the reacting foam chemical mix is dispensed on to a moving conveyer belt. The expanded foam develops in long flat loafs or buns (normally six feet wide). The buns are slit to its desired size, much like you would slice a loaf of bread.

Slitting - The process where sheets of foam are cut from a rectangular foam block.”

Sponge Rubber Cushion - Sponge cushion is manufactured with both synthetic and natural rubber along with other chemicals that include both oils and fillers. The mix expands when air is mixed into the batch by chemical means and is formed into either a flat or rippled slab. A material is bonded to the surface and this adds stability and provides a surface that the carpet can be stretched over. These cushions are made in widths up to 12′ and in weights between 41 and 120 ounces per square yard.

Flat Sponge (Slab Rubber) has a flat surface without the ripples.

Rippled Sponge (Waffle Rubber) has a rippled or waffled surface.

W X Y Z Sponge cushion is manufactured with both synthetic and natural rubber along with other chemicals that include both oils and fillers. The mix expands when air is mixed into the batch by chemical means and is formed into either a flat or rippled slab. A material is bonded to the surface and this adds stability and provides a surface that the carpet can be stretched over. These cushions are made in widths up to 12′ and in weights between 41 and 120 ounces per square yard.

Walk-on Testing - This is a standardized test that is used to evaluate installed residential carpet system performance. While this test can be used to evaluate different styles of carpet over a particular control system it can also be used to compare the affects of different types of carpet cushion on the composite floorcovering system. The complete protocol for this test is available through the Polyurethane Foam Association.

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