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Repetitive Odd Shaped Color Loss in Solution Dyed NylonThis report was commissioned by the mill.THE CARPETFIBER PROTECTANTS None Reported FIBER MANUFACTURER: Not Available FIBER/ ID METHOD: Nylon-Chemical COLOR: Multi-Colored Brown CONSTRUCTION: Tufted Loop STYLE: Level Looped SQUARE YARDAGE: 719 BACK SYSTEM: Action Back PRIMARY BACKING: Polypropylene SECONDARY BACKING: Polypropylene THE INSTALLATION TYPE OF SITE: Commercial TYPE OF BUSINESS: Manufacturer DATE INSTALLED: July 1996 METHOD: Direct Glue Down SUBFLOOR: Slab AREA INSTALLED: First & Second Floor Offices USE & MAINTENANCE INFORMATION AT THE TIME OF INSPECTION LITERATURE RECEIVED WITH PURCHASE: Not Determined NUMBER OF EMPLOYEES See Report TEMPERATURE: 68.6°F - 20.3° C RELATIVE HUMIDITY: 38% VACUUM TYPE: Upright FREQUENCY: Nightly ENTRY MATS: Yes CONDITION of THE CARPET: See Report SOIL: Slightly Soiled HEATING TYPE: Central Force Air Electric COOLING TYPE: Central - Electric CLEANING: See Report REASON FOR COMMISSION To determine the cause of spots in the carpet. THE REPORT Site Conditions and Geographical Information The carpet was installed in an office section of this new commercial building. The company designs and builds furniture and was occupied by 160 employees at the time of the inspection. Twelve employees worked in the office where the carpet was. The maintenance was being performed both in-house and by a professional service at the time of the inspection. Bakersfield is a medium sized city in the heart of the San Joaquin Valley in Central California. THE CLAIM HISTORY The carpet was installed just before the claimant set up offices in this facility and no immediate problem was noticed at first. After a short time spots began to appear in the downstairs carpet and increased in visibility with time. An attempt to clean one spot was made with no improvement. The claimant has an open house that will take place two weeks from the date of the inspection. This inspector did not share his finding with the claimant or the dealer at the time of the inspection, but did assure both parties that the report would be done quickly. The claimant and dealer expressed a strong desire to be given a copy of the inspection report and the inspector assured them also that their request would be passed to the manufacturer. DESCRIPTION OF PROBLEM AREA BY THIS INSPECTOR Oblong spots that were lighter than the surrounding carpet were noticed when entering the main work area of the first level. These spots had defined edges with part of one edge appearing to be almost straight and the remaining edges being more jagged. They were tapered on their ends running approximately four and a half feet and widening to approximate six inches. The spots were in a symmetrical groups of threes with the first spot starting at the seam and the second group at three feet and the third group at six feet from the seam. The second group of spots were similar in positions from the seam and were eleven or twelve feet down the length of the carpet. It was noted that the spots did have a tacky feel. The yarns had no visible differences in twist, bulk, or size. The hue of the yarn was consistent from one yarn to the next. The hue was also the same from the tip of the yarn to its base. No yarns were longer than the others. As to the spacing, the rows and columns was consistent. ON-LOCATION FIELD TESTING A Pile Direction Test was done using a piece of paper and a pencil. The pile direction of the spots was confirmed as running the same direction as the carpet. An inspection lamp was used in these two rooms for closer evaluation and to create shadows. This high intensity lamp is equipped with a 200 watt halogen bulb. The spots did not change in appearance. An ultra-violet light was shone throughout the installation. The result of this test revealed that there were no reflections. Numerous moisture tests were performed using a Delmhorst Moisture Sensor. The results of these tests revealed that there were no moisture readings. Numerous pH tests were taken using a digital type pH meter and a special low moisture probe that made direct contact with the face yarns. This device is accurate to ± 0.1 and was calibrated with a laboratory testing solution immediately before these tests were made. All tests were made using distilled water with a pH of 7.0. It was noted that as the moisture was applied, the water beaded on the spots and did not on the unaffected areas. The test results were as follows: affected areas 5.7 5.3 5.6 5.7 5.5 Ave. 5.56 non-affected areas 5.5 5.6 5.6 5.9 5.5 Ave. 5.62 A bleach test was performed using a test kit from COLOR MATCH SYSTEMS and revealed that there were no bleaching agents in the light spots. THE ISSUE OF THIS REPORT The question that I have been asked to address is: what has caused the spots? GUIDELINES FOR EVALUATING THE ISSUE Spots can occur when: 1. substances from manufacturing or installation 2. foreign substances have been split on to the carpet 3. lighting conditions create shadows on the carpet DEFINITIONS OF THE PROBLEMS According to the FLOOR COVERING DICTIONARY it says this about OIL SPOTS: Oil and grease spots will normally be found in a pattern either across the width in a pattern either across the width in a straight line or down the length in the same row of yarn. If they are caused by the mill, the will appear to be approximately the same distance apart. Oil and/or grease can usually be removed by cleaning with a solvent. If these spots appear randomly over the carpet, then they are mot considered a manufacturing defect and were probably caused by a local source. THE INSPECTOR'S ANALYSIS
When a spot is lighter than the surrounding carpet, the spot is missing color as opposed to something being added. In this case the color was fading. Since testing indicates that this condition was not created by maintenance related conditions, then installation and manufacturing are the two remaining possibilities. While doing the pH test the inspector noticed that water was beading momentarily in the affected area and not in the area that was unaffected. Since the affected area had a tacky hand, then the culprit is likely oil. The symmetrical pattern of the spots are thus explained by oil dripping onto the carpet during manufacturing. CONCLUSION The spots in the carpet in question are the result of fading from problems inherent in manufacturing based upon the location, shape, in-field testing, and background information provided in this report. |