How to Specify Contract Carpet on Commercial Projects
Specification 101: How to Specify Contract Carpet for Commercial Construction, Workplace, Healthcare, Hospitality + Senior Living Projects
Specifying carpet can be intimidating if you’re new to the process, or if you’re specifying carpet for a market sector that you don’t primarily work in. Worry not – this article will empower you with the right tools to make the best choice for your project.
The key components for understanding commercial carpet include fiber types, construction of the carpet, backings and sustainability considerations. We will delve into flooring and installation in a subsequent post. Now, let’s dig into the important characteristics when choosing carpet as your floor covering.
Fiber Types
The most common fibers found in commercial carpet include nylon, polyolefin and polyester.
Nylon is great for applications that require a durable carpet with a range of color options. Because nylon is positively charged (meaning it attracts negatively charged stains and spills), it is not inherently stain resistant, but topical solutions can be added to provide this characteristic. Nylon maintains its integrity anywhere from 5-10 years before showing signs of wear.
Polyolefin fibers are inherently stain and fade resistant, eliminating the need for a topical additive (which can wear off over time). However, because polyolefin is most often used in loop-pile construction, it is less resilient, meaning polyolefin does not easily bounce back to its original shape after pressure has been applied. It is less expensive than most fibers.
Polyester, like polyolefin, is also inherently stain and fade resistant. The advantages are color clarity, resiliency and its soft texture and wool-like appearance.
Two common yarn dyeing methods are 100% solution-dyed and Beck- or piece-dyed.
You can think of solution-dyed yarns like tomatoes: the color fully saturates the yarn as a result of the dyeing process. The pigment is added to the synthetic fibers before being twisted into yarn. The advantages of this process are that it’s the most color-stable option (meaning it won’t lose it’s color), it’s water and energy efficient, and it can withstand bleach solutions (not pure bleach!), which is great for healthcare applications, or any installation that requires deep cleaning. Solution-dyed nylon carpet is also recyclable, making it a go-to choice for most project types.
Piece-dyed carpets start as greige goods, which are then put into a pressurized dye bath (imagine a giant pressure cooker full of dye). Piece-dyed carpet is comparable to a radish: the color is found only on the outer layer of the yarn.
Because of technological advancements, both methods do well overall. It isn’t super important to choose one dyeing method over the other; it depends on the look you’re going for.
If you’re seeking endless custom options for color (or matching a Pantone color) and large scale pattern, check out post-dyed methods such as Milliken’s Printworks carpet: carpet tiles are cut to size, the pattern is then added on top and heated into the yarn, making it incredibly color-stable.
The actual shape of the fiber can also affect the durability and light refraction as well as ability to hide soiling and stains. Check out Mohawk Group’s Duracolor fiber construction for an example of quality fiber construction.
Carpet Construction
As important as the types of carpet, or maybe more so, is the carpet density is important because it determines how well the carpet wears and retains appearance over time from foot traffic, vacuuming and other activities indicative of a well-loved room. When tackling a project where the carpet is expected to last for 20+ years (such as convention centers, government buildings, schools, airports, etc.), be sure to take density into consideration. Use this TAR Rating fact sheet as a guideline for traffic levels. If you’ve ever heard the phrase 3.5 tarr thrown about that document will help you separate fact from fiction.
Woven carpets are extremely durable and great for high-traffic areas. Tufted carpet also works well, but the tufts may fold over and crush with pressure, showing wear patterns. If the tufts are sheared short, the carpet will show less wear patterns. Generally, flat, low pile carpets show wear much less than varying pile heights or carpets with more texture. Soft and fluffy-looking carpets are not great for high-traffic areas.
Broadloom carpet was often used in TI projects because of cost, however this has recently changed. Carpet tile has become higher in quality and less expensive in recent years due to advancements in technology and manufacturing processes. While broadloom is still less costly per square yard, there are many benefits to specifying carpet tile:
Corridors are often narrower (8’ wide for example) than broadloom widths (12’ wide), meaning installers have to cut a wide strip to fit the corridor, producing unnecessary waste. Carpet tiles produce much less waste.
Carpet tile installation is also easier on installers’ bodies. They can apply adhesive and install carpet tiles standing up, instead of being on their knees for extended periods of time installing broadloom carpet.
Tiles are easy to swap out if there’s a spill or damage. New tiles may look discernibly new when surrounded by older carpet tiles, but – pro tip – you can take an old tile from an area that is a bit less noticeable or not in the main corridor, replace in the area of the spill, and install the new tile in the obscured area.
Backings & Adhesives
Backings
A cushion backing aids in resiliency and helps avoid showing signs of wear. Milliken offers “WELL Back Cushion” and “Back Cushion Plus,” which are also helpful for installations with a lot of moisture content. The felted cushion backing is made of open-cell construction, which lets the carpet breathe and allows moisture to evaporate, helping mitigate moisture issues.
Another backing that helps control moisture – specifically spills that come from above (versus coming up from the slab below) – are moisture barrier backings. Some carpet manufacturers, such as Mohawk Group, use membranes with technology that allow vapor to pass through from below (from the slab as it dries in new construction), but block moisture from above (spills), keeping it out of the carpet.
Broadloom backings differ from carpet tile backings, as broadloom carpet is constructed like a textile (stretched over a screen-like backing). You can upgrade backings to add a latex or polymer layer that binds tufts tighter, and can protect against zippering and raveling, ensuring they stay bound into carpet. You can also add carpet pads that the broadloom will be stretched on top of (versus glued).
Adhesives
Adhesives used to contain toxic solvents, but these days most are water-based. Look for adhesives that are Green-Labeled, low-VOC, or meet strict California requirements. Water-based adhesives can cause moisture issues such as peeling or wrinkling in the carpet if the slab has high moisture content.
Milliken offers “TractionBack,” which adds a tackiness to the backing – a good choice for installing without adhesives in areas with high moisture levels. Mohawk Group offers “Flexlok” tabs as an adhesive alternative, linking carpet tiles together. These can be used in situations with high moisture, or if the subfloor is wood that shouldn’t be damaged with water. The tabs will work in conditions up to 99% RH (relative humidity), whereas the water-based adhesives begin to lose their bond above 85-90% RH.
Sustainability & Health
Perkins and Will’s transparency page makes it easy to look up various substances – their uses, concerns, and what types of building products they are most often part of.
Some manufacturers make it easy to check a product’s attributes and environmental certifications on the spec sheet - see page 2 of this sample specification.
Did you know? Source makes it easy to search for products free of specific chemicals and additives. You can also search for specific certifications and labels, as well as manufacturers that are doing good things for the environment and their communities.
You also need to be aware of the carbon footprint produced by carpet manufacturing, transportation from factory to your project (this also includes trucking old carpet to recycling centers after it’s lifetime), and the carpet’s lifetime. Carbon handprints help offset carbon footprints, and some manufacturers make this a priority to help offset carbon emissions. Many manufacturers provide bags with prepaid labels to make returning samples easy. Returned samples are restocked to be used again.
If your project requires ripping out a large quantity of old carpet that cannot be reused as carpet in a different project (such as donating to Habitat for Humanity), there are ways to divert the old carpet from the landfill. One inspiring example involves the renovation of the Oregon Convention Center, repurposing the old carpet to effectively filter the water being pumped into Puget Sound.
Another option is to look into manufacturer recycling programs: Shaw Contract’s re[TURN] program will take back Shaw EcoWorx carpet at the end of its life, and recycle the material into a new EcoWorx product.
Shaw Contract shared an example of strict carpet specification requirements for the San Francisco Department of Environmental Regulation. Here is an example of carpet specification criteria based on the strict San Francisco requirements, which can be used as a general guideline for specifying healthier carpets.
Biophilic design and science-based design are becoming more common in the design world, due to an increased interest in the health and wellbeing of occupants. Fractals have been researched for over 30 years, measuring the relaxation response to fractal patterns. Mohawk Group’s “Relaxing floors” line blends art and science.
Specifying for Different Market Sectors
For projects that are considered severe-traffic, such as education, healthcare, airports, civic buildings, etc. (any building that is used frequently by the public), carpet is expected to have a 20-30 year lifetime. Important factors to consider for these long term installations are durability, high density woven construction (for resiliency), high quality backings, fibers that hide soiling, and stain resistance (look for lifetime stain warranties).
Workplace projects are considered moderate- (private offices and conference rooms) to heavy-traffic (corridors), and don’t require as many considerations as the previous category. Multi-tenant offices often expect carpet to last only 5-10 years before switching tenants. Look for stain-resistant properties or topical treatments.
Hospitality projects consider beauty more important than performance. This is because hotel rooms are intentionally turned over every 5 years or so, after lots of heavy use and messes. Hotel managers don’t need all the bells and whistles, they want it to look great more than being ultra-high performance.
Senior living projects have very specific considerations. Pile height and texture is important, as carpet that is too bumpy can pose a trip hazard. Transitions between materials need to be AFAP (as flush as possible) to assure that shuffling feet, scooters, walkers and wheelchairs can easily pass over them. Pattern and color are also important considerations. Aging eyes perceive color and pattern differently. As we age, our eyes add a yellow tint to our vision – you can use yellow-tinted glasses to look at finish palettes to help make design decisions. Dark colors and high contrast can be perceived as a dizzying dropoff or a hole in the carpet. It is best to stay in mid-tones, with medium contrast. Soft striations, organic and abstract patterns are better than busy geometric designs, as aging eyes can register busy patterns as stressful or scary objects. Moisture barrier backings are common within units, especially in memory care.
Source Says
The “Coffee Spill Test,” informally coined by interior designer Roberta Pennington, is a test to see how well a carpet pattern will hide coffee stains. Order a sample of carpet, take a bit of black coffee – a strong, espresso blend is preferred – and spill in a grapefruit-sized area of the sample to check how obvious the stain is (you can never assume the stains will be properly cleaned once installed).
If you’re on a budget, go with a simple pattern layout. Complex installs with multiple patterns intermixed are more expensive, sometimes by up to 25-30% because the installers must refer to a layout plan to place each tile, which takes a lot more time and labor!
Don’t love any of the standard carpet edge trim options? Check out Schluter Systems, which are designed for tile edges but work wonderfully for carpet as well! (Hint: Schluter-SCHIENE is perfect for transitioning from carpet to concrete). Profilitec is another similar option.
Use Source’s quick reference for material pricing guidelines
Quick Ship carpet options are helpful for fast-paced projects, or if you need a carpet in a pinch (say a carpet pattern you specified a year ago has been discontinued). Quick Ship can ship anywhere from 3 days to 2 weeks depending on the manufacturer, but be sure to check the quantity limit as they may not have enough in stock if it’s a large project.
Carpet weight (ounces of fiber per square yard) often drives the price of carpet. You can look for the weight on the back of carpet books. In general, for TI projects, 20oz - 25oz is a good bet for your budget. For carpet that won’t be changed out for 20 years, look for around 40oz, which will be pricier.
Take advantage of free resources offered by carpet manufacturers. Their websites often allow you to create carpet layout drawings quickly and easily, download high-res images for presentations, or offer online software for creating custom designs. Check with your rep to see if they have a team that can put together a 3D room rendering of your space with the specified carpet pattern. And, if you are low on time, ask your rep to help select carpet options that fit your criteria.
Common issues or problems usually occur during installation – floor prep, moisture testing or adhesives, or there is a manufacturing defect. If you run into a problem, contact your rep and they will work with you to resolve it as soon as possible. Choose from manufacturers that stand behind their products and encourage your GCs to choose flooring subs that stand behind their craftsmanship and labor. Something likely will go wrong on a project, so aim to put together your best team!
Develop relationships with your reps and ask questions! They’re here to help you through the process, from the very beginning to post-install.
Additional Resources
https://blog.manningtoncommercial.com/specify-commercial-carpet-a-designers-guide
https://living-future.org/declare/declare-about/red-list/#red-list-and-watch-list-casrn-guide
https://shawfloors.com/flooring/how-to/carpet/how-it-s-made/comparing-carpet-fibers
Portland Material Transparency Collaborative http://www.pmtc-pdx.org/
https://blog.millikencarpet.com/buying-carpet-stop-falling-for-these-5-carpet-specification-myths
Author
Maddy Gorman, NCIDQ | Interior Designer
Disclaimer
While we hope you find an incredible amount of value in this article, we surely haven’t been able to cover the broad swath of applications and particular circumstances that will come up on every project. We encourage you to connect directly with your manufacturer’s rep regarding the specific specification needs of your project.
You can find your local manufacturer’s rep in the world’s largest commercial construction rep directory here. Grab their contact information, or send a message right on Source. Happy specifying!
