Introduction

The very first carpets were made by hand-knotting lengths of yarn into a woven substrate, and indeed fine hand-made rugs continue to use this method of construction.

During the 18th Century, advances in technology allowed the process to be automated such that carpets were woven together on looms. In particular, two factories based in Wilton and Axminster were early adopters of this new production method, wherein continuous strands of yarn are woven to create loops in between the warp and weft of the backing material. Good quality carpets continue to be manufactured in this manner.

Early in the 20th Century, a new, faster and cheaper method of carpet production was invented. These are the tufted carpets which are created by needle-punching loops of yarn into backing a material onto an adhesive substrate.

Finally, the cheapest form of carpet is created by bonding a web of tightly packed fibres onto a pre-formed backing. Most often, these will be cut into carpet tiles, which are particularly useful in industrial and commercial applications.

Having been woven or tufted, carpets are finished in one of the following three ways;

Cut Pile Carpet

In this type of carpet the loops are sheared to create individual upright fibres. Examples of cut pile carpet include;

• Velvet (also known as Velour and Plush) has short pile fibres created by several stages of cutting to create a very smooth surface with a sheen that will show footprints and track marks.
• Saxony carpet is usually made of thicker yarns than velvet, with a deeper pile, making it soft and warm, but susceptible to tracking marks. A more textured version is available wherein fibres have a greater degree of twist and show fewer marks.
• Frieze (also known as Twist Pile, Hardtwist and Hightwist) has an even longer pile made of both straight and highly twisted yarns that produce a more casual appearance that will not show track marks.
• Shag Pile has the deepest pile available to create a coarse and highly textured look.

Loop Pile Carpet

In loop pile carpets the loops remain in tact to form a continuous uncut surface. For example;

• Level Loop carpets (also known as Berber) have all loops created the same height. This dense surface can have a ‘corded’ look which resists crushing and is well suited to high traffic areas.
• Patterned Loop carpets have loops of yarn in two or three different heights which may be arranged to create a regular or random pattern.

Cut & Loop Pile Carpets

These carpets includes both complete loops and sheared yarns, possibly in mixed heights, to create a large variety of patterns and textures.

Carpet Construction

Other than the fibre itself, there are three further qualities of a carpet that will determine its overall durability. Together they contribute to the overall weight of the carpet. Heavier carpets tend to cost more, but will retain their appearance for longer than cheaper, lighter weight carpets.

Twist

Twist refers to how tightly the filaments in each tuft of yarn are twisted together. This carpet quality is measured per inch, where the greater the number, the more twisted the yarn is and therefore the less susceptible the carpet is to crushing and matting.

Density

Density is a measure of how thick each yarn is and how closely the tufts are spaced. This may be measured in stitches per inch, and a greater density will allow the carpet to resist crushing. If you can see the backing when you bend the carpet, it has low density.

Pile

The pile height, or nap, is the distance between the backing material and the top of the tufts of yarn. A deeper pile will provide a plush look, but is prone to crushing so that tracks can be left in the carpet. A shallower pile looks less luxurious but is firmer so will retain its appearance.

Carpet Grading system

The British Carpet Classification Scheme distinguishes each carpet according to its durability and offeres suitable applications. Listed below are the domestic classes;

• Light domestic - suitable for Bedrooms
• Medium domestic - suitable for Dining Rooms
• General Domestic - suitable for Living Rooms
• Heavy Domestic - suitable for Stairs and hallways

Further information and useful links

• Carpet materials
• Tools & tips for measuring a fitted carpet
• Guide to installing a fitted carpet
• More floors topics

• Find a Carpet supplier near you
• Find a Carpet Fitter near you