rugs

Tufted Rug Construction

I love it when my worlds collide, with a background in product design and having my own decorating business I am fascinated to learn how the products we buy and love are made. Last week I attended a seminar presented by Delos Rugs at J&S Designer Flooring and was so excited to learn more about their rug construction. With different construction methods, materials, and styles the options are seemingly endless, so in this post I will focus on how tufted rugs are made. I think it's hard to visual the process so I've included lots of video to demonstrate how it works! Have fun looking around!


Design Phase 1: image source Delos Rugs

Color Selection Phase 2: image source Delos Rugs

To Begin

There are many steps involved before you can actually begin creating the rug, such as design, color selection, pattern transfer, and many more. Once you get to the tufting stage you create the rug by pushing the yarn through a fabric backing with a tufting gun, like this image shown below. Here are the key steps in the tufting process from CRI (Carpet & Rug Institute)

  • Yarn comes from cones on creel racks (or from big spools called beams) into the machine.
  • The primary backing feeds into the machine.
  • Yarn and primary backing come together in the machine (full shot of machine)
  • Yarn is fed through needles on a needlebar of a tufting machine. Needles repeatedly penetrate or tuft into the primary backing.
  • The tufted carpet is mended and inspected.
  • Carpet is rolled onto large rolls for the next step (whether it’s to be dyed or to be backed.)

(image source)

Types of Tufting

There are also several ways a tufted rug can be made:

- Hand tufting with handheld gun

- Hand tufting with automatic gun

- Machine tufting

 

Finishing

There are many steps involved in finishing a rug, and most depend on the style and design. In order to keep the yarn in place, all tufted rugs have a layer of latex that is painted or sprayed on the back which serves as glue. Then a piece of fabric is laid on top which covers the latex and the generally messy looking back from the tufting process. That's actually one way you can tell if a rug has been tufted is if it's covered on the back. 

(image source)

It sheds from shearing...

The face pile of a tufted rug needs to go through some finishing steps, which include shearing to create a flush uniform surface. Depending on the design the yarn fibers are color sorted by hand to keep the pattern clean and defined. Sometimes the edges are even carved for a more dimensional look. The first video is a bit dated but it shows all the steps concisely: latex, shear, carving. 

This second video shows an alternative carving tool. 

 

The End...

Well actually that's only a small fraction of one type of rug construction but I hope you enjoyed these videos as much as I have! It's great to learn and gain a better understanding of what goes into a tufted rug so you can see the value of what you are buying and be an informed consumer!

Cheers, 

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A Project Update

I'm excited to say that our first personal home project of the new year was to refinish the hardwood floors! It all started innocently enough, just peeling back the corners of our carpeting to see what was underneath. Then we couldn't help ourselves and just ripped it all out. 

Ever since we moved into our home we have been discussing the pros and cons of hardwood vs wall to wall carpet. I love hardwood for that timeless classy look, the design flexibility that area rugs provide, as well as easier cleaning when living with a very furry pet.

It's been a busy few weeks moving furniture, ripping out old carpet, and pulling a trillion staples. Things got much easier once we switched the tools we were using and started pulling staples with the vice grip shown on the stair below. That worked wonderfully and if you have a similar job in your future I'd highly recommend getting one!

Considering that our house is older we knew there was a chance for some bad stains and potential repairs, especially since previous homeowners had laid ceramic tiles directly onto the hardwood as shown above. There was a rough moment while they were working when they couldn't get the diamond pattern out. The tiles had trapped in moisture and darkened the wood underneath. They were afraid it went too deep into the wood and they suggested we begin discussing plan B. But luckily (so so lucky) for us they ran the sander a few more times and it came out! HORRAY!!

And as you can see they were able to work miracles with our 55 year old floors! The grout sanded up fine and it looks fantastic! The stairs are not done in this photo yet, they were finished today. I plan on showing more finished pictures soon, and you might guess that I will be posting information and resources for area rugs and runners in the future ;)

Thanks for reading! More to come later... 

Cheers, 

Send an Email | call 973.944.0188  |  like us on Facebook  |  Follow us on Pinterest  |   Talk on Twitter

You can sign up for our monthly email newsletter by clicking here!!

And now on instagram!

Pantone Products

I've been reading a lot about color lately and was excited to see the most recent catalog from The Home Decorators Collection featuring four new lines of rugs that are part of Pantone Universe! There is Pantone focus, Pantone expressions, Pantone prismatic, and Pantone matrix.

This first picture from their catalog that shows a simple shag in the Pantone 2013 color of the year, of course: Emerald.  One of the other colors available is Tangerine Tango which was 2012's color of the year. These are basic color block options for a dose of saturated color in any room.

This catalog page shows their more subtle color combinations which all have a soft feathered edge to the patterns. I really like the one they picked to photograph above, called New Antique. You'll also see they've selected a few Pantone chips on each page so you can "perfectly match your wall color, laminates, furniture, accessories and more with our rugs."

 

I also liked these tone on tone geometeric wool flatweaves shown above. 
Horizon Blue: Pantone 19-4057 TPX and Pink Flambe 19-3138 TPX