IDCEC Course # 102822, Subject Code 5.8, BasicAIA Course #000202, Provider #G391

©2013 The Carpet and Rug InstituteIDCEC Approval 12/18/13 – 2/1/16

Registered Provider G391The Carpet and Rug Institute is a Registered Provider with The American Institute of Architects Continuing Education Systems

This CEU is registered with the Interior Design Continuing Education Council (IDCEC) for continuing education creditsArchitects Continuing Education Systems.

Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-

(IDCEC) for continuing education credits. This credit will be accepted by the American Society of Interior Designers (ASID), International Interior Designers

AIA members are available on request.This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed

Association (IIDA) and Interior Designers of Canada (IDC). The content included is not deemed or construed to be an approval or endorsement by IDCEC of any materialit does not include content that may be deemed

or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, di ib i d l i i l d

or endorsement by IDCEC of any material or construction or any method or manner of handling, using, distributing or dealing in any material or product. Questions

l d ifi i l h d ddistributing or deal in any material or product. Questions related to specific materials, methods and services will be addressed at the conclusion

related to specific materials, methods and services should be directed to the instructor or provider. This program is registered for .1 CEU be add essed at t e co c us o

of this presentation.eg ste ed o . C U

(continuing education credit).”

Course Objectives

At the end of this course, the participant will be able to:

Describe the fiber manufacturing processg pList the benefits of various fibersExplain how yarns are processedExplain how yarns are processed.State the characteristics of fibers and yarnsDistinguish between various fibers and yarnsSummarize reasons to specify for performancep y p

Carpet and Rug Fiber Market Share

Wool and Other1%

Triexta11%

Nylon 48%

Polyester 48%

y25%

Polypropylene15%

Natural FibersWoolWool

Natural fiberNatural fiberStaple fiberDurableDurable ResilientS lf ti i hiSelf-extinguishing when burned1% of market1% of market

Synthetic FibersExtrusionExtrusion

Every synthetic fiber is extruded:

N l (T 6■ Nylon (Type 6 and Type 6,6)

■ Polypropylene■ Polypropylene■ Polyester (PET)■ Triexta (PTT)( )

Synthetic FibersExtrusionExtrusion

Extrusion Process Diagram1 Blended polymers and1. Blended polymers and

colored pigments2. Spinnerettesp3. Cooling tower4. Yarn take-up

And, once extruded, a fiber becomes a continuous filament.

Synthetic – NylonFeatures and BenefitsFeatures and Benefits

FeaturesTwo types: 6 and 6,6

BenefitsExcellent wearabilityTwo types: 6 and 6,6

BCF or staple fibersWhite dyeable or solution d d

Excellent wearabilityResilientResistant to abrasion

dyedWide array of deniers, lusters and cross sections

Easily cleaned Permanent and inherent stain resistance and colorfastness

Virgin fiber and recycled fiberApprox 50% of market

resistance and colorfastness (solution dyed)

Approx. 50% of marketPredominant fiber used in commercial marketSignificant fiber used in residential market

Synthetic – Polypropylene

Solution dyed fiber onlyMostly BCF (or staple for needlepunched carpet) Colorfast/resists fadingGenerates low levels of static electricityResistant to acid-based stains and to water-based stainsResistant to moisturePrimary fiber for indoor/outdoor carpetApproximately 15% of marketpp y

Synthetic – Polyester

Features BenefitsVirgin and recycled PETBCF or stapleS l ti d d hit

Resistant to acid-based stainsEasily cleanedSolution dyed or white

dyeableInherent and permanent stain

Easily cleanedColor clarityColorfastness (solution p

resistanceUsed in residential market

(dyed)

Approximately 25% of market

Synthetic - Triexta

Features■ BCF fiber

Benefits■ BCF fiber■ Inherent and permanent stain

resistance

■ Excellent colorfastness and bright colorsD bili

■ Solution dyed or white dyeable■ Entry point is residentially

■ Durability■ Resistance to fading

(solution dyed)y p yfocused.

■ Approximately 11% of market

(solution dyed)■ Cleanability■ Texture retention■ Texture retention■ Luxurious “hand”

Synthetic Yarn Production

BCF Fiber

B lk d

Staple Fiber

Si l hBulked Continuous FilamentLong strands of

Simulates short fibers found naturally in woolRequires fourLong strands of

fiber form yarn bundles Then require one

Requires four steps to form yarn bundle: 1. Blendingq

or more processes:1. Plying2. Air entangling

g2. Carding 3. Drafting4. Spinning

3. Twisting 4. Heat-setting

p gTwisting and heatsettingNot as predominant as BCF fiber

Synthetic Yarn Production

Synthetic Fiber Characteristics

Each fiber manufacturer creates a fiber

l

Each fiber manufacturer creates a fiber with certain specific characteristics:

■ Polymer type

■ Cross section

■ Luster

■ Denier

Therefore, every fiber has its own ID.

Cross Section

Cross section is h h f hH H i the shape of the

individual filaments of yarn Fine Denier

ib

Human Hair Conventional BCF Fiber

Cross section is determined by the h l i th i t

BCF Fiber

holes in the spinneret during extrusion.

E h fEach manufacturer of fiber has its own specific shape.

Magnified 200x - the fiber size is smaller than aMagnified 200x - the fiber size is smaller than a human hair

Synthetic Fiber ProductionFiber Cross Sections

Shape affectshthese carpet

properties:LusterBulkinessTexture retentionS il hidiSoil-hiding abilities

Denier and Cotton Count

Denier is used to measure BCF (Bulked Continuous Filament)

Denier describes the filament size of the yarn.Multiple filaments make up a yarn bundle

Continuous Filament)

Multiple filaments make up a yarn bundle.The larger the denier, the larger the yarnThe smaller the denier, the softer the yarnThe smaller the denier, the softer the yarn Less than 900 denier (small) to more than 3000 denier (large)

Yarn bundle: individual filaments bundled

htogether to create a single yarn strand.

Denier and Cotton Count

Cotton Count is used to measure Spun/Staple Yarnsp p

■ Cotton count is an indirect yarn count system■ The smaller the cotton count, the larger the yarn in

staple/spun.4 00 ( ll) 2 25 (l )■ 4.00 (small) to 2.25 (large)

Yarn Processing

Prior to tufting or weaving, yarn may be g g y yprocessed in one or more of the following ways:

Air EntanglingAir EntanglingAir TwistingPl T i iPly TwistingTwisting and heat setting

Yarn Processing: Air EntanglingEntangling

Yarn Twisting – Air Twist Process

Provides excellent color separationseparation

Allows for twisting 2-ply to 6-ply yarns in one step for dd d li fl ibiliadded styling flexibility

High speed operation

Excellent performance characteristics in loop pile carpet

Yarn Processing: Ply TwistingTwisting

Several colors ply twisted together

Si lSingles yarnPly twisted yarn

Cut Pile Yarn Twist

Yarn twist affects appearance i d h i f llretention and aesthetics for all

carpet constructionsM d i TPI T I hMeasured in TPI – Turns per Inch

High twist: 6 or greater TPIMedium twistLow twist: 3 TPI or less

Heat-setting

Heat-setting is a continuous process to stabilize the yarn twist.

SuessenUsed mainly for spun yarny p yUses dry heat

SuperbaSuperbaUsed mainly for BCF yarnUses steam

Anti-Static Properties Added to FibersAdded to Fibers

Static InhibitorsSpecific fiber blendsSpecially engineered fibers (with carbon filaments)

End UsesImportant to maintain a proper balance of relative humidityGeneral commercial, 3.5 kV is acceptable maximum valueCritical commercial environments (data processing) – kV isaccepted upper limitaccepted upper limit

How Should Specifications Be UsedSpecifications Be Used

To achieve desired performance andTo achieve desired performance and aesthetic objectives:

A by product of the performance criteriaA by-product of the performance criteriaA by-product of the aesthetic needsA by product of the flooring budgetA by-product of the flooring budget

To obtain optimal flooring results for all of th di d f th k t lthe diverse needs of the marketplace.

Construction and PerformancePerformance

Specifications They are TotallyInterrelatedPerformance is overriding factorPerformance must be blended with Color/Pattern/DesignPerformance is achieved by the right

bi ti fcombination of elements

Elements of a Manufacturing Specification

Yarn ConstructionC C iCarpet Construction Dyeing MethodTreatmentsBacking Systemg y

How Does Construction Affect Performance?Affect Performance?

Construction largely determines performance.Construction consists of many yfacets, each playing a role:

FiberYarnDye MethodDye MethodCarpet Manufacturing ProcessesBacking SystemBacking System

Performance Features

Specifier specifies certain performance

Stain ResistanceStatic Resistance

certain performance features based on end use requirements:

Stain ResistanceStain ResistanceSoil ResistanceStatic DissipationAnti microbial Protection Li htf tAnti-microbial Protection Moisture ResistanceLightfastness

Lightfastness Soil Resistance

Warranties may support these performance features.

Carpet Specification:Pattern and Color

S lid H th R d P ttSolid Heather Random Pattern

Hides Least Hides Most

Preventive Measures for All Fibers

Outside Mats/Tiles:Scrape debris offUse coarse texture matsC h ld ilCan hold soil

Inside Mats/Tiles:Purpose:Purpose:

1. Removes dirt and moisture2. Dries wet soil for vacuuming3 Confines soil to one area for easy removal3. Confines soil to one area for easy removal

At entrances and any high-soil area

Clean inside and outsideClean inside and outside mats/tiles frequently.

Summary and Q&A

Topics DiscussedFiber manufacturing processFiber manufacturing processBenefits of various fibersCharacteristics of fibers and yarnsyPerformance specifications

The Carpet and Rug Institute100 S H ilt St t D lt GA 30720100 S. Hamilton Street, Dalton, GA 30720

706.428.2123carpet-rug.org

BibliographyCRI: The Carpet Primer. The Carpet and Rug Institute, 2002CRI: Model Specification for Commercial Carpet, 2012Carpet and Rug Institute. (multiple pages about fiber selection, how to specify and buy carpet, installation and p g ( p p g , p y y p ,

maintenance of commercial carpet. www.carpet-rug.org, 2013“Carpet Basics.” The Carpet Site: An Online Consumers’ Guide to Carpet and Other Flooring Products.

http://www.thecarpetsite.com, 2008“Fiber and Yarn Basics.” Contract Sales Training. Shaw Learning Academy, Center for Sales Excellence, 2012.Floor Covering Weekly: The Industry’s Business News & Information Resource, “Carpet Industry Statistics,” 2013 Floor Focus Magazine. Floor Daily. http://www.floordaily.net/FloorFocus, 2009How Carpet Is Made. Mohawk University, Mohawk Industries, training video 2001Invista. http://www.invista.com, 2011p ,J&J Flooring Group, Images, 2013Mohawk Industries. http://www.mohawkind.com, 2013Quinstreet, Inc. The Carpet Buyers’ Handbook. Forest City, CA 2013 Solutia Inc http://solutia com 2012Solutia Inc. http://solutia.com, 2012Wools of New Zealand, USA. Wool Research, Inc., Industry Website, http://www.woolsnz-partner.com/industry“Yarn and Carpet Manufacture.” Floor Tech: Understanding the Flooring Industry. Shaw Learning Academy, Center

for Retail Excellence, 2011The Carpet and Rug Institute CEU Workgroup members meet every six weeks to discuss and edit content for all CRIThe Carpet and Rug Institute CEU Workgroup members meet every six weeks to discuss and edit content for all CRI CEU courses. The CEU Workgroup is composed of technical and marketing managers from companies such as Shaw, Mohawk, Beaulieu, Bentley, Interface FLOR, J&J/Flooring Group, Tandus | Centiva, Milliken, Atlas, Dow, Solutia, Invista, Shell and others.