Carpet Construction & Durability

Here's an overview of the steps involved in carpet construction.

Bulked Continuous Filament (BCF)
Continuous strands of nylon are formed into yarn. They are also texturized to increase their bulk and to change from straight into kinked or curled fiber.

Twist
Each carpet fiber is wound around itself to make the carpet pile more resilient. The tighter the twist, the more the carpet will resist crushing, matting and changes in texture.

Heat Setting
After the fiber is twisted, it is treated with heat to lock in the twist. The result: carpet fibers that won't easily unravel or crush under heavy foot traffic.

Tufting
The heat-set fiber is fed through needles and then stitched or tufted into the primary carpet backing. The density of a carpet is determined by how much yarn is used and how close the tufts are to one another.

Dyeing
The tufted carpet is saturated with liquid dye then treated with a fixation solution and dried.