Carpet flooring is something most of us take for granted, especially when it comes to the interesting, somewhat complicated manufacturing process.  A little knowledge goes a long way. When you have insight as to the different materials and processes used, it will help you make the most educated decision on selecting the right one for your needs. After all, you'll be living with these materials for a long time, and flooring is one of the biggest investments you'll make in your home.

Tufted yarns: the first step

Almost all yarn clusters are created with a tufting machine.  Very few, in fact, less than five percent of carpets (even wool), are handwoven these days. Tufting machines have rollers and a lot of needles (like 12,000 of them) that pull the yarn through the backing. Then small hooks take each yarn to create a loop; special sensors control the size of the loop to determine just how plush the rug will be.

After that is the dying process, which may be either done by boiling the rug in a large tub of water, dye, and chemicals;  silk screening or embossing.  The latter is done with large rollers; it's similar to wall painting when a textured appearance is desired.

Carpet options

High pile rugs, such as the shag and frieze, have long, loose fibers.  Low piles, such as the Berber, have short, tightly woven threads.  The Berber is a looped pattern, not cut and looped as some. The Saxony has different styles, from a plush, velvety appearance to a patterned one.

Also, know your fibers, such as natural wool and synthetics like nylon, polyester, olefin, and Triexta.

The best thing is to discuss with your carpet flooring retailer. Tell him or her exactly how and where you plan to use it, so you find the best choice for your needs.

By the way, here’s a fun fact:  Your rug could have once been a milk or soft drink container. Most synthetics are polymers; in fact, nylon has a big plastic content.

To learn about your carpet options, visit the First American Carpet & Floors showroom in  Woodbridge and Stafford VA.  We service Woodbridge, Stafford, Triangle, Fredericksburg, Lorton, Manassas, Dumfries, and Lake Ridge.  Ask about our estimates.