d Note to Presenters: Regular typeface script Italics typeface suggested activities or additional information FYI
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1 Welcome to this course on secondary carpet backing systems and treatments. This hour is one of six CEU courses about Carpet Specification Basics developed by the Carpet and Rug Institute, the national trade association for the carpet industry. The other courses cover other aspects of carpet manufacturing: Carpet Construction, Fibers & Yarns, Dye Methods, Carpet Specification and Carpet Test Methods. In addition, CRI offers a number of other CEUs on market segments and sustainability. (Optional: Those are listed at education/index.cfm.) d Note to Presenters: Regular typeface script Italics typeface suggested activities or additional information FYI Suggested demo materials: All types of secondary backings (without brand names) Optional: Jar of binder material/latex Plexiglass with backing adhered to it either showing good seaming or showing a cut out that has been replaced. CRI Fact Sheet, Taking the Guesswork out of Specifying Carpet: a 6-Step Plan using Texture Appearance Retention Ratings, carpet-rug.org. 1
2 This course has been approved by the American Institute of Architects and by the Interior Design Education Council. 2
3 Topics we will be covering include: The backing process Types of backing systems Technical features of different systems Treatments Shearing And, at the conclusion of the course, participants will be able to Enumerate the benefits of backing carpet Identify the main types of backing systems Identify elements that should be included in a backings specification. Identify the technical features of protective treatments We ll close with a question and answer time. 3
4 All carpet has some type of backing system that helps keep the tufts in place. Depending on the performance requirements of the backing and the carpet, varying methods and chemicals will be used. The type of backing system depends upon the end use of the carpet and the type of space where the carpet will be installed. There are a variety of specialized systems for high performance applications, which will be discussed later in the course. The yarn is first tufted into the primary backing and then a secondary backing system is attached. 4
5 Commercial carpet backing systems are more numerous and varied than those for residential use. Each fulfills a specific function. Secondary backing systems often consist of a polymer binder with or without a secondary backing. In the most common backing system, the yarn is secured into the primary backing by synthetic binder material, and a secondary backing (most commonly woven synthetic) is attached to provide further pile-yarn dimensional stability. 5
6 Or the carpet may be woven, in which case the backing is an integral part of the woven construction because the yarns themselves form the backing. Most woven carpet is coated with some type of binder material for stability, normally 2 10 ounces per square yard. Additionally, woven carpet may have a cushion backing added for comfort underfoot. 6
7 In the carpet industry all manufacturers test their backing systems with a variety of certified and industry tests to evaluate performance in many areas. The test methods are shown here (and for a more detailed discussion of carpet test methods, we do offer another CEU #204 that details all carpet test methods.) In the next few slides, we ll be discussing the benefits of backing systems Briefly review each backing benefit and each definition. Dimensional stability is the ability of a textile material to maintain its original size and shape. In the photo a carpet tile is being tested for dimensional stability. Good tuft bind exists when there is an adequate amount of binder material on the back of the carpet to encapsulate the tufts and prevent them from being pulled out of the carpet. Good backing systems also provide resistance to zippering, which occurs when fibers can be pulled out of a row of loop pile tufts thereby creating a gap in the fiber coverage. Tuft Bind and Zippering are measured by ASTM D1335. Optional; may mention if you re also using the Carpet Testing Methods presentation after this presentation. When we discuss Carpet Testing Methods later in our presentation, we ll be elaborating on each of the test methods by which these benefits are evaluated. 7
8 Other benefits of backing systems include durability and resistance to edge ravel. Briefly review each backing benefit and each definition. If you have access to backing samples (without brand names), you could show those. Durability is defined as the ability of carpet to maintain its appearance and performance features over time. It s measured by a Hexapod test, which is ASTM D5252 or by the Vettermann Drum, ASTM D5417, or by the Roller Chair Test, ASTM D6962. Resistance to edge ravel is another feature of an effective backing system for loop pile carpet. Edge ravel occurs when the edges begin to ravel at the seams. This can be measured by ASTM D Optional; may mention if you re also using the Carpet Testing Methods presentation after this presentation. When we discuss Carpet Testing Methods later in our presentation, we ll be defining each of the test methods by which these benefits are evaluated. 8
9 Backing systems with moisture barriers from the base of the pile yarn to the floor prevent spills from penetrating the backing and seeping into the sub-floor and help eliminate stain wick back, which is the resurfacing of the stain on the floor as it rises back through the fibers. Moisture barriers may be valuable where spills are inevitable and cleaning is frequent, or for certain healthcare environments. The moisture barrier of the carpet itself and the sealing techniques for the seams may provide lower long-term maintenance costs. Moisture management in backing systems is evaluated by the Dynamic Crush Test and the British Spill Test. The carpet backing arena is developing quickly. Specifiers should stay in contact with carpet manufacturers for the latest in backing technology innovations. Optional; may mention if you re also using the Carpet Testing Methods presentation after this presentation. When we discuss Carpet Testing Methods later in our presentation, we ll be defining each of the test methods by which these benefits are evaluated. 9
10 Other benefits to backing systems include Resistance to delamination. Resistance to pilling and fuzzing Delamination occurs when the secondary back or the attached cushion separates from the primary backing. The picture on the top right shows the test for measuring delamination. Resistance to delamination is measured as the force per unit of carpet width required to peel the secondary backing or attached cushion away from the primary backing. Pilling and fuzzing occur when individual fibers are visible as fuzz on the surface of the carpet. Backing systems encapsulate or coat the fiber bundles on the back of the carpet, helping to prevent pilling and fuzzing. This is a test using a hook and loop roller. 10
11 Many flooring manufacturers are involved in green technology. A prime example of this environmental initiative is found in certain high-performance backing systems for commercial carpets. These backing systems contain one or more of the following components: highly-refined mineral compound recovered from electric utility power plants; reclaimed carpet backing or recycled content; or polymers created from domestically grown soybeans, a rapidly renewable resource. Additionally, some backing systems use other non-carpet post consumer materials; and others use methane gas collected from landfills in manufacturing advanced latex backing, thereby employing renewable energy sources which result in reduced emissions. Still, other manufacturing techniques for backing systems use rapidly renewable bio-based resin which reduces our dependency on petrochemicals by 10 million pounds annually. 11
12 Manufacturers in the carpet industry have submitted their backing products and systems to achieve various certifications. NSF/ANSI-140 Sustainable Carpet Standard Developed by a diverse, multi-stakeholder group including federal and state government representatives, end users and manufacturers, the Sustainability Assessment for Carpet, or NSF 140, is the first multi-attribute ANSI-approved environmental standard for building materials in the US. The standard: Evaluates multiple product attributes over the entire life cycle of a product Covers durability, recycled content, carpet recovery programs, and life cycle impact reductions such as emissions, i energy and waste, among others. Provides the third party authentication Clarifies some of the complicated environmental subjects and assist specifiers and end users in making informed product decisions CRI s Green Label Plus Certification Test methods developed in cooperation with the EPA and are administered by independent lab (Air Quality Sciences). Each sample is individually tested Dynamic environmental chamber technology Test methodology has been adopted by ASTM as D5116 Standard Guide for Small-Scale Environmental Chamber Determinations of Organic Emissions from Indoor Materials/Products EPA Green Power Leadership Awards or IAQ Tools for Schools Leadership Award ISO Manufacturing facilities can be ISO certified, which is the highest environmental standard for a manufacturing plant. Note: CRI has additional CEU courses that explain these certification processes in more detail: CRI NSF-140: The Green Carpet Standard and CRI-601 Green Label Plus Testing: Carpet, Cushion and Adhesives. 12
13 Demand continues to grow for building materials that fulfill the requirements of the nonprofit U.S. Green Building Council (USGBC) Leadership in Energy and Environmental Design (LEED). The benchmark certification program for green building projects and buildings that carry the LEED seal of approval are a statement of environmentallyconscious practices. In addition, studies show that energy-efficient LEED buildings cost less to operate, have higher occupancy rates, enhance occupant health and well-being and increase investment returns compared to their non-leed counterparts. Most carpet backing systems contribute to LEED credits for recycled content, low emitting materials and innovation in design. However, backings have a greater contribution value in commercial interiors (LEED CI) and existing buildings (LEED EB) than in new construction. 13
14 Backing, Finishing or Coating is the last step in a typical commercial carpet manufacturing process for the majority of tufted and woven carpet manufactured in the U.S. This process may include applying one or more layers of binder materials to the primary backing and in many cases joining the primary backing with a secondary backing. The secondary backing is typically coated separately prior to marriage to the precoated carpet. During the finishing operation for commercial carpet, protective treatments may be applied, such as soil and stain resistant chemistry and/or anti-microbial treatments. Stain resist treatment can also be applied earlier in the manufacturing process. Typically, the carpet goes then through a drying oven, if the process requires the removal of excessive moisture, which helps develop backing strength. (Shown in diagram above.) However, some of the newer extruded backing systems are finished using a cooling process. After the steps discussed above, the carpet may be sheared and brushed to remove any loose fibers and create an even surface. 14
15 We will discuss the backing systems based on type: backing for broadloom, backing for tile or backing for woven carpet. In CRI s Preparing a Commercial Carpet Specification, using the Model Specification for Commercial Carpet, you can find carpet specification forms for these carpet types: Broadloom with unitary backing Broadloom with synthetic secondary backing Broadloom with polymer backing other than latex Broadloom with attached polymeric cushion backing Broadloom with moisture barrier, polymeric non-cushion backing Tile carpet Tile carpet, cushion backing Broadloom carpet, woven As we discuss the features and benefits of the various backing systems, it would be good to note which backings features you feel are most important in various end use segments, so that you can write those requirements into your specifications. Guidelines are available at 7_Model_Specifications_Commercial_Carpet.pdf. Image: Jenkins-Peer Architects 15
16 Depending on the commercial application and market segment in which the product will be installed, there are a wide variety of backing systems available with different features and benefits. The following categories of backing systems are used for broadloom, carpet tile and woven carpet. For example, for broadloom, there are three types of thermosets that are latex emulsions, including regular, high performance and cushion. Or, for carpet tile backings that are thermoplastics, those can be divided into polyethylenes, polyolefins and PVC. In addition, there are also some specialty products that don t fall into any of these categories. It s important that specifiers check the manufacturer s warranties on all backing systems to determine if they have selected the best one for the specific end use. 16
17 Synthetic binder material (also know as latex) is the industry standard for backing broadloom, and it is also used for woven carpet. This type backing is created by the dispersion of solid materials into water, i.e., polymer binder. In commercial carpet, products in this category are either unitary (which means the binder material is coated on the back of the carpet and then it s finished without a secondary backing) or secondary (which means the binder material is put on the back of the carpet and then a secondary backing is added.) Unitary backing provides good tuft bind, delamination and edge ravel strength. This type backing is not used for patterned carpet. If a secondary backing is added, d this can help provide excellent pattern match characteristics. If possible, show a piece of carpet with latex unitary and with latex/secondary backing. Remember, ActionBac is a trade name and shouldn t be used to describe latex with secondary backing even though it s commonly used in the carpet industry to denote this backing. Nor should any mention be made of the various carpet manufacturer s trade names for latex unitary. 17
18 Typical polyurethanes are backing structures formed by reactive chemistry. Once formed, materials cannot be reheated and softened again. Polyurethanes can provide moisture management capabilities and comfort underfoot, with attached cushion. This backing type offers excellent tuft bind and edge ravel resistance and improved appearance retention. Again, remember that Enhancer is a trade name of Dow s and shouldn t be used to describe this type backing, nor should any company brand names that might be used to designate this type of backing system. If possible, show an example of this backing system. 18
19 Thermoplastics are materials that become soft when heated and solid when cooled to room temperature. This can be repeated over and over. Polyolefins, Poly Vinyl Chloride (PVC), Poly Vinyl Butyral (PVB), Polyethylene Terephalate (PET), and EVA (ethylene vinyl acetate) backings are all considered thermoplastics, although they have somewhat different characteristics. Thermoplastic backings provide dimensional stability, excellent wet and dry tuft bind along with excellent delamination and edge ravel strength. In addition, they provide moisture management properties, are recyclable, provide comfort underfoot and improved appearance retention when attached cushion is used. They also provide thermal insulation. Show examples of these backing systems if you have pieces that are not labeled by a manufacturer s name. 19
20 Several tile manufacturers offer other backing systems. For example, one offers a backing made of proprietary content which is a by-product of the forestry industry. Another offers a reinforced carbon composite backing system; and another a non-chlorinated polymer recycled from the film found in windshields and safety glass. The industry continues to explore new types of backing systems. 20
21 Depending on the end use of the carpet, various treatments may be added during the finishing process, for example stain resistance, soil resistance and anti-microbial protection. Stain and soil resistance are different. Stain resistant chemistry can be added to help the carpet fibers withstand spills and stains. Soil resistant chemistry can be used to help the fibers resist tracked-in soil and dirt. Anti-microbial chemistry can also be added either to the backing or the face fibers or both. 21
22 Protective treatments aid in preserving carpet appearance by repelling soils. The most common treatments used in the carpet industry are fluorochemicals. During the 1970 s topical fluorochemical treatments were introduced to protect carpet fibers, typically nylon and polyester. Fluorochemicals retard soiling by coating carpet fibers with a low surface energy, film-forming polymer. Fluorochemicals function by not allowing soils to stick to the fiber surface; therefore, when the fibers are cleaned, the soil is released. Fluorocarbons function at relatively low add-on levels so they provide a protective barrier without impacting other desirable fiber properties such as hand, luster or shade. Fluorochemical chemistry has advanced to provide treatments that offer good durability to traffic, cleaning and abrasion resistance. Fluorochemical treatment of carpet is done by millapplied surface application and can be applied to many carpet constructions and most fiber types. 22
23 Stain-resist treatments or stain blockers on nylon have had a significant impact on carpet for residential i use. Some unprotected nylon carpets are readily stained by foods containing i acid dye colorants. To retard staining, stain-resist treatments are used in conjunction with antisoiling chemistry to produce a protective system. Stain-resist treatments provide a barrier mechanism against many common food stains. Many nylon products for residential and commercial usage in the U.S. offer a stain-resist protector. 23
24 It should be noted, however, that these treatments are enhancements; they do not make the carpet stain-proof. For example, carpet treated with a stain-resistant finish is still subject to stains if the spot is not removed promptly and properly. Chemical treatments are also not a substitute for the preventative measures of vacuuming and extraction cleaning. To avoid using chemical agents that might react with the finish or may void the manufacturer s warranties, follow the manufacturer s recommendations for spotting and deep-cleaning methods. 24
25 Biocides (which could be Antimicrobials, Fungicides and Bactericides) can be used as a treatment during the finishing process for carpet. They serve to help reduce the growth of microorganisms. Carpet backing can be chemically treated to reduce the growth of mold and mildew. Anti-microbial treatments help to providing broad spectrum activity against growth. The presence of anti-microbial treatments can be tested using AATCC 174. (American Association i of ftextile Chemists and Colorists) Some manufacturers will offer anti-microbial treatments in the backing or on the face fibers on a custom basis. Most of these treatments are branded and must be EPA registered. STRESS: Clean, dry carpet is not a food source for mold and mildew. 25
26 In order to clean up the surface of the carpet, it will pass through a shearing unit, resulting in a clean, groomed surface. The shearing heads brush the carpet pile to make it both erect and uniform, and then pass it through a series of rotary knives or blades that shear or cut off the fiber tips at a precise height. Multiple-head shears have a double set of hard bristles or nylon brushes and two, three or more shear blades per unit. The shear head action is like a rotary blade lawnmower. The shear is also used for tip or random shearing, an effect that creates a textured look. When a tip-sheared carpet is specified, the carpet is tufted as a multi-level loop carpet. Loops significantly longer than the others are formed for subsequent cutting by the shear. The cut fiber tips showing on the surface against the loop pile background give darker or shaded cut areas and surface interest to the carpet. Tip shearing can be an integral part of the carpet design or pattern. Pattern effects can also be achieved with a hand or computerized shearing. In pattern shearing, carpet rides along a rotating, hard rubber composition belt that carries a raised design. As the carpet rides along the raised portions of the design, the shear cuts a level surface, creating a high-low, three-dimensional appearance to the carpet. 26
27 After the various steps of the backings process have been completed, the carpet must undergo a final inspection before it is rolled, wrapped and stored for shipment 27
28 Today we ve discussed the backing process, various types of backing systems, treatments and final shearing and inspection. We appreciate your participation. For additional information about backing systems, you may visit the Carpet and Rug Institute website or contact a manufacturer s representative. 28
29 If you are a member of AIA, we encourage you to submit your course evaluation online at the CES Discovery page for AIA members. 29
30 30
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