For a long time now, you have been reading my complaints with patterned carpet and the mills inability to keep the patterns straight. This is a perpetual problem particularly in the commercial carpet segment.

BOW, SKEW,WAVER

Bow, skew and waver in the pattern has stressed out more than a few carpet dealers and installers, I'm sure. Years ago, I learned a saying, If you don't control the carpet, the carpet will control you. Now, there's a new tool to help.

SYNTHETIC INDUSTRIES

Recently, I had the opportunity to visit Synthetic Industries to take a look at their new primary carpet backing called Pattern Loc. This new primary backing has some unique features, which will aid the carpet manufacturer in keeping the patterns straight throughout the manufacturing process.

Pattern Loc features a True Line placed every three feet across its width. This line, woven into the backing, is the guide by which the carpet manufacturer can visually control the straightness of the pattern.

Pattern Loc also has a unique edge which minimizes dog boning. This term describes the heavier, thicker, edge on conventional primary backing products.

BACKING

By minimizing dog boning, the carpet is easier to control on the finishing lines and ,in particular, the tentor frame, where the primary and secondary backings are married. This is the place where much of the pattern bowing and skewing occurs.

Pattern Loc is manufactured in a separate location in the mill operated by employers given special training to insure the product is a straight and true as is possible. The challenge is now for the carpet manufacturer to invest in this backing. Pattern Loc is about 5% more than normal primary backing, but that's a small investment considering the alternatives.

Patterns, which are bowed, skewed or wavered generally, make it to the job site that way. When the installer opens the roll and sees what he has to work with there’s usually no choice but to start installing the job. Since every job must go in, there’s not much alternative.

Even when the mill sends out its own people to see whether the carpet can be properly installed, it may take eight hours to make a 50-ft seam. This may prove the carpet can be installed with a matched pattern but in the real world, no installer, regardless of his skill, can afford the time or expense of languishing on the job site just to make the pattern straight. That’s the mill’s job, and Pattern Loc gives them the opportunity to do just that.

Pattern Loc is not a miracle backing that will allow the carpet to be manufactured at light speed while maintaining an arrow straight pattern; it is a tool by which the manufacture of the carpet can be gauged and controlled. It requires diligence to insure that the pattern is straight.

Problems with pattern bow, skew and waver create very large claims. Since much patterned carpet gets installed out of square, most of it either has to be taken up or be adjusted with a substantial monetary settlement. If the carpet has to be pulled up, the furnishings, including all of the electrical and communications lines, will have to be moved. When calculated, this undertaking, including re-installation, can cost upwards of four times what the broadloom costs. Not the size claim anyone wants.

With a tool such as Pattern Loc, used as it was intended, the mill can eliminate or minimize claims on pattern bow, skew and waver. There is a visible means by which to determine exactly what direction the carpet is going across the width and how to correct the condition or keep the broadloom aligned consistently. This product is a necessary invention since the problem of pattern bow, skew and waver is epidemic. The problem is caused by not controlling the carpet. If everyone would just slow down, controlling the carpet would be a whole lot easier. Since that’s not likely to happen, Pattern Loc should, at least, help you get a patterned carpet that’s easier to install.

The tool is in place, now it needs to be used correctly. This is a small price to pay to eliminate a huge claims problem.