|
|
Yarn slippage - Improper CushionThis report was commissioned by the mill.THE CLAIM STATISTICS PROBLEM REPORTED: Yarn Slippage SAMPLES FROM INSPECTION: None Taken PERSONS PRESENT: Inspector & Claimant THE CARPET FIBER/ ID METHOD: Nylon-Chemical FIBER HUE: Off White CONSTRUCTION: Tufted Cut Pile YARN STYLE: Cable Yarn SQUARE YARDAGE: 326 BACK SYSTEM: Conventional Tuft PRIMARY BACKING: Polypropylene SECONDARY BACKING: Action Back THE INSTALLATION LOCATION TYPE: Residential METHOD: Stretch-In CUSHION: 1/2 Inch Rebond 3.5 Lb./Cu. Ft. SUBFLOOR: Concrete on the First Level, Ply-wood on the Second Level. AREA INSTALLED: Living-Room, Dining-Room, & 3 Bedrooms USE & MAINTENANCE INFORMATION AT THE TIME OF INSPECTION LITERATURE RECEIVED WITH PURCHASE: Not Reported TEMPERATURE: 81.9°F - 27.7° C RH 42% ADULTS: 2 - CHILDREN: 0 - PET(S): 1 - Cat DO THEY SMOKE? No SPOTTING AGENTS: Shout by Johnson's Wax VACUUM/FREQUENCY: Built-In Every Other Week ENTRY-MATS? Yes SOIL: None Noticed HEATING TYPE: Central Force Air Gas COOLING TYPE: Central - Electric CLEANING: Never Been Cleaned REASON FOR COMMISSION To determine the cause for the pulled loops. THE REPORT Site Conditions and Geographical Information The carpet was located in the claimant’s free standing 8000 square foot two story house. This house was located in a gated rural community. The house was well maintained and was owner occupied at the time of the inspection. BACKGROUND INFORMATION MADE TO THE INSPECTOR No problems were noticed at the time of the installation. Approximately 10 or 11 months later sprouting tufts were noticed. This problem got progressively worse with time. DESCRIPTION OF PROBLEM AREA BY THIS INSPECTOR Sprouting loops were noticed in trafficked areas. They did not conform to individual stitch or gauge, straight, or diagonal lines. Whereas the yarn height was approximately 3/4 of an inch, pulled loops were approximately 15/16 of an inch. Loss of twist was noted to be normally 1/4 of an inch. Latex was still attached to yarns that had been pulled free. The carpet was pulled back and:
The claimant’s vacuum cleaner was inspected and the brush was the non-motorized stationary type. No probably culprit for pulling yarns was found. ON-LOCATION FIELD TESTING A sample of the claimant’s cushion was weighed by the inspector to determine the cushion density. This test consisted of weighing a one foot square of the cushion. The cushion height was divided into one foot and then multiplied by the weight. This test was performed on an electronic scale from Acculab, model number: V-333. This device is accurate to .1 grams. The results of this test showed a 3.45 pounds per cubic foot density. Fifteen Tuftbind Tests were performed over a remnant. The results were as follows:
THE ISSUE OF THIS REPORT The question that I have been asked to address is: what caused the carpet yarns to slip and then sprout? GUIDELINES FOR EVALUATING THE ISSUE Pulled loops can occur when: 1. there is excessive foot traffic and/or improper proper maintenance 2. there is a manufacturer’s defect 3. there is a failure to meet minimum standards of installation Sprouting tufts occur when there is loss of twist on pulled-loops from foot traffic INDUSTRY STANDARDS & DEFINITIONS The DEPARTMENT OF HOUSING AND URBAN DEVELOPMENT ASSISTANCE SECRETARY FOR HOUSING FEDERAL HOUSING COMMISSIONER sets the standards for minimum tuft-bind called UM44D. For cut-looped carpet this standard is 48 ounces or (3 pounds); for looped carpet the standard is 100 ounces or 6.25 pounds. The DEPARTMENT OF HOUSING AND URBAN DEVELOPMENT ASSISTANCE SECRETARY FOR HOUSING FEDERAL HOUSING COMMISSIONER sets the standards for minimum cushion thickness and density. For Bonded the standard is:
The Carpet Cushion Council also recommends Class 2 for stairs and hallways." Concerning carpet cushion on Residential stretch-in-installations the CRI105 says this from page 14: 9.5 Cushion Installed Wall-to-Wall Cushion should be securely fastened to the subfloor with staples or nonflammable cushion adhesive around the perimeter of the installation. Seams shall be secured with staples or nonflammable cushion adhesive. However, tape -- such as duct tape -- shall be used for most seams on rubber cushion. These procedures are used to prevent shifting of the cushion during and after the installation. Foam cushion seams are to be covered with vinyl coated fabric tape (duct tape) or secured with adhesives. Staples or adhesives are to be applied 6 inches (150 mm) within the perimeter edges all around. 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. THE INSPECTOR'S ANALYSIS Two people and a cat living in an 8000 square foot house with stationary head vacuum cleaner does not constitute excess usage or maintenance problem. Thus usage and maintenance are not likely culprits in creating yarn slippage and fuzzing. When yarn slippage is inherent in manufacturing there are problems in the latex. Tuft-bind testing evaluates the latex’s ability to hold the yarn in place. The results from this test on this carpet showed the tuft-bind strength to be 4.2 times that of the Federal Standard and should be considered far in excess of the minimum requirement. Thus no pulled loops could be attributed to manufacturing defects. The U.S. Government requirements for FHA-finance housing for separate-carpet-cushion are called HUD UM72 and the Carpet Cushion Council has endorsed this standard as a minimum recommendation. For over 20 years they have been proven to work. In addition the Carpet Cushion Council has conducted their own testing for performance and have shown that these standards are a minimum guideline for standard carpet performance. Better grades of carpet cushion are suggested when more support is needed. In this case the usage is light, but the cushion is only 80 per cent of a minimum requirement and 42 per cent of what would be required in a Class 2 situation. Thus it should be considerably inadequate. Not placing duct-tape over cushion seams is an industry wide practice despite the fact that the CRI105 requires it. In this case problems that were purely associated with this problem were not noticed, but its effect could be synergistic with the lack of power-stretching and inadequate cushion density. When substandard cushion density is combined with a lack of power-stretching, the effect on the latex is synergistic. Thus, the latex begins to break down, the yarns slip raising above the plain, and then begins to bloom. CONCLUSION Yarn slippage and sprouting in the carpet in question was due to problems inherent in the installation and not in manufacturing based upon the test performed and the measurements taken. |