Bands from Shearing
This report was done for a carpet mill.
THE CARPETFIBER/ ID METHOD: Nylon-Chemical
FIBER HUE: Very Light Beige
CONSTRUCTION: Tufted Cut Pile
YARN STYLE: Saxony
SQUARE YARDAGE: Not Given
BACK SYSTEM: Conventional Tuft
PRIMARY BACKING: Polypropylene
SECONDARY BACKING: Action Back
THE INSTALLATION
LOCATION TYPE: Commercial
TYPE OF BUSINESS: Apartment
DATE INSTALLED: 10/15/97
METHOD: Stretch-In
CUSHION: 1/2 Inch Rebond
SUBFLOOR: Plywood
AREA INSTALLED: Living-room, Dining-Room, Hallway, & 2 Bedrooms
USE & MAINTENANCE INFORMATION AT THE TIME OF INSPECTION
LITERATURE RECEIVED WITH PURCHASE: No
TEMPERATURE: 70.1°F - 21.1° C RH 67%
ENTRY-MATS? Yes
SOIL: None Noticed
HEATING TYPE: Wall Unit - Gas
COOLING TYPE: None
CLEANING: Never Been Cleaned
REASON FOR COMMISSION
Determine if roll crushing has taken place and fix the problem.
THE REPORT
Site Conditions and Geographical Information
The carpet was in a single-level unoccupied apartment that was located in the Los Angeles Basin, near the foot of the Hollywood Hills. This apartment was a part of a small complex and was managed by the owners.
BACKGROUND INFORMATION MADE TO THE INSPECTOR
During the installation, lines were noticed by the claimant and installer, but the installer finished the job and recommended vacuuming to fix the problem. During vacuuming, the claimants vacuum cleaner ‘jumped’ when moved on to the problem areas. No changes in appearance have taken place since the problem was noticed.
DESCRIPTION OF PROBLEM AREA BY THIS INSPECTOR
Dark bands running the width of the carpet were noticed in the living-room and two bedrooms. Their appearance would change when viewed in different directions, but were always visible. When viewed directly overhead they appeared as texture variations, instead of hue differences.
In the 18 feet long living-room, the band started near the front of the room at:
· four feet and ran to four feet seven inches and started again at
· eight feet nine inches and ran to nine feet five inches and started again at
· 13 feet nine inches and ran to 14 feet two half inches.
In the next 17 foot four inches long bedroom where there was a private entrance and the problem was most intense they started near the front at:
· one foot four inches and ran to four feet, five inches and then got darker at
· four feet five inches and ran to five feet two inches and started again at
· eight feet six inches and ran to nine feet two inches and started again at
· 12 feet eight inches and ran to 13 feet four inches.
In the second 11 feet six inches long bedroom, they started at:
· two feet three inches and ran to three feet zero inches and started again at
· five feet six inches and ran to six feet four inches and started again at
· eight feet 11 inches and ran to nine feet six inches.
ON-LOCATION
FIELD TESTING
A Pile Direction Test was done using a piece of paper and a pencil and was confirmed that the pile direction of the bands was the same direction as the carpet.
An inspection lamp was used for closer evaluation and when the light was brought down low it made the bands darker.
A portable steam machine was used to attempt corrections. Slight improvements were made temporarily.
THE ISSUE
The question that I have been asked to address is: what has caused the carpet to develop lines?
GUIDELINES FOR EVALUATING THE ISSUE
Widthwise Lines Can Be Caused From
1. Storage from Roll Crushing
2. Manufacturer’s defects from
· stop marks
· tension variations on the beam
3. Installation errors
· improper bending or fold marks
INDUSTRY STANDARDS & DEFINITIONS
According to the FLOORCOVERING DICTIONARY is says this about FOLD MARKS:
FOLD MARKS - Exposing carpet to contaminants that leave a yellow color band or stain on the carpet is the probable cause of a fold mark. Narrow lines cased by creases in the carpet during storage.
According to the FLOORCOVERING DICTIONARY is says this about BAND:
BAND - Abnormal color variation extending across the width of a carpet, usually grater than one yard in width. Bands may be caused by stops (fairly well defined bands) or uneven application during continuos dyeing (less defined at starting and ending edges).
THE INSPECTOR'S ANALYSIS
Most of the bands ran approximately eight inches and did not fit the definitions of fold marks or creases. Since they were darker than the surrounding carpet when the light was brought down low, they are likely variations in the shearing process that cut the yarns below the field. As such, tip shearing would not be a practical remedy for fixing the problem.
CONCLUSION
The lines in the carpet in question were due to bands created in shearing in the manufacturing process based upon tests done at the time of the inspection.