Buckling From Power Stretching in Length & Poor Latex
This report was done for the dealer. The mill agreed to pay half of the claim.
THE CARPET
FIBER/ ID METHOD: Nylon
FIBER HUE: Brown & Tan
CONSTRUCTION: Tufted Loop
YARN STYLE: Multi-Level Loop
SQUARE YARDAGE: 300 +
BACK SYSTEM: Action Back
PRIMARY BACKING: Polypropylene
SECONDARY BACKING: Polypropylene
THE INSTALLATION
LOCATION TYPE: Residential
DATE INSTALLED: 11/95
METHOD: Stretch-In
CUSHION: Super Lock
SUBFLOOR: Concrete
AREA INSTALLED: Living-Room, Master Bedroom, Stairs, Office
USE & MAINTENANCE INFORMATION AT THE TIME OF INSPECTION
LITERATURE RECEIVED WITH PURCHASE: None Reported
TEMPERATURE: 58.2°F - 14.5° C RH 51%
ADULTS: 2 - CHILDREN: 0 - PET(S): 0
DO THEY SMOKE? Not Applicable
SPOTTING AGENTS: None
VACUUM/FREQUENCY: Canister Weekly
ENTRY-MATS? Yes
SOIL: None Noticed
HEATING TYPE: Central Force Air Gas
COOLING TYPE: Central - Electric
CLEANING: Never Been Cleaned
REASON FOR COMMISSION
The carpet has reportedly buckled.
THE REPORT
Site Conditions and Geographical Information
The carpet was installed in the claimant’s free standing four story house, located in a residential neighborhood in the Beverly Hills. The house was well maintained and was owner occupied at the time of the inspection.
BACKGROUND INFORMATION MADE TO THE INSPECTOR
Reportedly the carpet was installed on a cold day without a chance to acclimate to a warm temperature. A few months later it began to buckle. Also, pulled loops were realized that got progressively worse.
No corrections had been attempted at the time of the inspection, but the claimant had commissioned an Inspector to perform an inspection. His report indicated that problems were inherent in manufacturing caused by defective latex.
DESCRIPTION OF PROBLEM AREA BY THIS INSPECTOR
Three ridges were noted in the master bedroom running the length of the carpet. Also, on the fourth level a ridge was noted next to the baseboard.
The carpet was pulled back and the latex felt unusually brittle and powdery. The holes from the tackless-strip-nail were oblong in the secondary backing in the length but not in the width.
Pulled loops were also noted on some steps in the stairway and in the living-room.
ON-LOCATION FIELD TESTING
An ultra-violet light was used to draw a reflection from substances with optical brightening agents. Yellow reflection will come from most urine stains; a blue or lavender reflection from detergents. The result of this test revealed that there were no reflections.
Numerous moisture tests were performed using a Delmhorst Moisture Sensor. This test would indicate the presence of moisture locked-up in salt compounds from urine and detergents. The results of these tests showed no moisture throughout the installation.
A remnant sample of this carpet was sent to Independent Testing Laboratory Inc. of Dalton Georgia for DIMENSIONAL STABILITY OF PILE YARN FLOOR COVERING DUE TO MECHANICAL ACTION. The results of these tests were as follows:
Average un-recovered extension (length 1.8%
Average un-recovered extension (width) 1.7%
Total average: 3.5%
THE ISSUE
The issue of this report is whether power stretching can fix the buckling.
GUIDELINES FOR EVALUATING THE ISSUE
Ridges can be caused by:
1. errors in manufacturing
2. errors in installation
3. improper usage
There is no covering authority that has set standards for un- recovered extension or dimensional stability.
INDUSTRY STANDARDS & DEFINITIONS
Concerning Temperature and Humidity with respect to Site Conditions the CRI105 - 1994 says this:
5.2 Temperature and Humidity - Carpet should be installed when the temperature is between 65° and 95° F (18° C. and 35° C.) and the relative humidity Is between 10% and 65% and, if installing over concrete, the slab temperature should not be less than 65° F (18° C).
Concerning power-stretching, the CRI105 says:
9.14 Power Stretching - Following seaming, carpet must be power stretched and firmly hooked onto the tackless strip at the starting walls in surrounding area. The use of a power stretcher is mandatory.
Before power stretching, make certain that hot melt tape seams are cool to the touch.
A four-way stretch is to be used. (See Figures 3-5)
Follow the carpet manufacturer’s recommendations for the method and amount of stretch to be applied.. When recommendations are not available, tufted carpet with jute secondary back should be stretched "drum-tight." Tufted carpet with synthetic secondary back should be stretched 1 to 1 1/2% in width and length.
THE INSPECTOR'S ANALYSIS
Three facts about this carpet that have influenced buckling and are factors in correcting the problem are:
1. A cold temperature is a significant factor in creating buckling and if the temperature of the house was similar to the 58.2 degrees Fahrenheit experienced on the day of the inspection, then there is high probability that the problem is correctable by raising the temperature over 65°F. for 48 hours and restretching the carpet. The reason behind this is because carpet must relax in order to stretch.
2. When holes in the secondary backing from the tackless-strip-nails are oblong in the length and not in the width, there is a strong likelihood that power stretching has occurred in the length only. Pulling any elastic material in one direction will create ridges. This problem too could be fixed by re-power stretching the carpet in the width.
3. When latex is brittle and powdery, then clay and/or filler content in the backing material is likely unusually high. Since carpet backings are made of clay, filler, and latex, decreasing the latex in favor of the other ingredients. Restretching often has to be done repeatedly with diminishing results.
While DIMENSIONAL STABILITY does not have official standards, a combined percentages greater than three percent was not acceptable in years past. Furthermore a percentage less than 2.5 was required to consider the carpet good. Currently some mills would say that yarn style and woven backing material would be a factor in determining a higher acceptable percent on this test. Independent Textile testing services Inc. also reports that most carpets tested in recent times measure between 2.5 to 4.0 percent. For this style the best guess as to the mills’ assessment would be that 3.5 percent would be the upper limit on acceptability. This in and of itself would seam unacceptable for a high end carpet.
Moreover a high clay and filler content may also be affecting ‘bundle-wrap and penetration’ of the latex to the yarn. Once again official standards for bundle-wrap and penetration do not exist, but lower percentage with respect to this can account for pulled loops as noted by the claimant and inspector during the inspection.
CONCLUSION
Buckling in the carpet in question cannot be satisfactorily fixed by restretching due to a defect in the latex inherent in manufacturing. This conclusion is based upon testing at an independent testing laboratory, the stiffness of the carpet, and the powdery state of the latex.