Broadloom carpet

Carpets that are right for the task at hand.

HOW broadloom carpet is constructed and what it’s made from dictates performance and appearance, so understanding the difference is important to ensure correct specification.

Choose the wrong carpet for the task and it will certainly cost more than it needs to, whether through premature-wear or over-specification.?

Woven carpet
Weaving is the most traditional way to make carpet and to this day, remains the best way to make carpet for commercial use. To make a woven carpet, a loom interlaces face yarns – generally wool or wool blend – and a backing yarn of jute or a synthetic alternative. Once the carpet is removed from the loom, a thin coating of latex is applied to the back to fix the tufts in place.

The principle is roughly the same for the two types of woven carpet readily available; Axminster and Wilton.

With the Axminster method, the most ubiquitous of the two in commercial environments, each individually coloured yarn is selected by the loom, cut and inserted as a ‘U’ shaped tuft wherever needed, often to create intricate patterns.

Axminster weaving leaves most of the yarn on the surface, giving Axminster’s famed quality and comfort. Wilton weaving generally involves fewer colours with the yarn running continuously, either at the surface or in the back. Wilton is less flexible in design but can be used to bring varying texture.

A reputation for heavyweight, lasting quality means Axminster weaving is favoured in commercial interiors, where it can provide a carpet with the ability to withstand high-levels of daily footfall.

Often highly patterned, it also has excellent soil-hiding properties, making it popular in busy hospitality and leisure environments. Ideal for use in areas such as receptions, staircases and function rooms, Axminster quality is dictated primarily by the number of rows, generally ranging from six through to 10 or higher. The latter reserved for the most demanding areas and when exceptional design definition is required.

It’s not uncommon for Axminster carpet to be used throughout high-end projects, altering the number of rows to provide tailored wear performance in different areas. For example, in a high-end hotel a seven-row Axminster may be used in bedrooms, a nine-row in corridors and a 10-row in function areas and reception. The construction method is also popular in hospitality locations because of its ability to produce complex designs, involving up to 12 colours and with an unlimited pattern repeat size.

In contrast, Wilton carpet can be created in varying textures and so is the preferred weaving method where a loop pile – known as ‘Brussels weave’ – or cut-and-loop texture is preferred. Using fewer colours and with restrictions on pattern repeat size, designs tend to be less opulent, more geometric and just like Axminster carpet, quality is altered through row count, a higher number indicating better wear-resistance.

Tufted carpet
Primarily a residential style, tufted carpet can be appropriate in low-wear commercial environments. It is made on a machine that can be likened to a giant sewing machine, but with more than 1,200 needles rather than just one. Each of these needles is threaded with an individual colour and stitched into a pre-made primary backing. The ‘face’ loops of each tuft can be left un-cut to create a loop-pile carpet or sheared to create cut-pile carpet.

Patterning is achieved by shifting the needles side-to-side in sequence. A secondary backing is applied to provide additional stability and comfort.

A great choice in lower wear areas where durability is less of a concern, such as hotel bedrooms, tufted carpet provides excellent value.

High quality wool-rich varieties can also be used in corridors of boutique style establishments, or in public areas of residential developments and with simple designs possible, such as stripes or basic geometrics, tufted carpets can also help to disguise soil.

Tufting is a much quicker carpet production method compared to weaving and this is why it’s default carpet type in the residential sector, where limited pattern capability and the ability to hide dirt is less of a concern. In commercial environments where pattern is used not only to enhance interior design, but also improve dirt hiding and appearance between cleans, it’s less favoured.

However, it’s used in commercial environments where there’s less need for lasting-quality, or in breakout zones and boardrooms where luxurious textures, such as high-lustre polyamide deep cut-pile styles, are in demand.

Carpet fibre
Other than a tufted or woven construction, one of the biggest factors to impact carpet is the choice of fibre. For tufted carpets, fibres will either be polypropylene, nylon or wool. In woven carpet, fibres are generally wool or wool-rich.

Polypropylene is a man-made fibre that is cost-effective to manufacture, and which comes with inherent stain-resistance. This makes it a popular choice in value-orientated tufted carpets. Polypropylene fibres are coarse and stiff and don’t recover as well as other carpet fibres, and so are prone to flattening in areas subject to constant traffic.

Another man-made fibre, nylon is a more durable than polypropylene and so is used in high-end tufted commercial carpets. Soft and durable, it’s also available in different lustres and deniers, making it a versatile fibre that can be used to create interesting textural effects.

Nylon is also available in solution-dyed qualities, where colour is part of the make-up of the fibre, for permanent stain and fade-resistance.

As a carpet fibre, wool has a reputation for durability and quality, and unquestionably so.

Though, like anything, there are good and bad wool carpets and a lot of this is down to the quality inherent in the fibre itself. Some breeds of sheep make for a more resilient fibre with better dye-take, in-turn leading to a carpet that’s lasting and rich in colour.

British wool is one such fibre, with over 60 breeds and the UK climate contributing to a carpet fibre that is resilient to footfall and with excellent recovery. 100% natural and renewable, British wool also has more bulk than other readily available sources, helping the carpet’s pile to perform well against wear in busy spaces.

With these natural properties, it’s easy to see why wool has long been favoured in woven commercial carpet and in recent times wool-blend woven carpets have become the norm. Again, quality here is dependent on the ratio and the fibres used. In order to retain the properties of wool and not to compromise performance, a blend of minimum 80% wool is desirable, preferably mixed with nylon’s excellent longevity.

Carpet design
When it comes to carpet design, there is no doubt that woven Axminster is king and it is the best option when lasting pattern in high-wear areas is demanded. As another benefit, highly-patterned Axminster is also great at hiding soil between cleans, making it ideal for busy venues.

There have been significant advances in woven carpet manufacturing, with modern high-speed Axminster looms. Computer controlled and automatically fed, these looms mean it’s now possible to quickly switch between designs.

Carrying 12 colours, which can be changed quickly, high-speed looms help carpet manufacturers to provide both bespoke pattern and colour without the lengthy and costly downtime faced on traditional looms.

Ready to Weave carpet design
For many projects, the cost of a completely bespoke design can be prohibitive, so some carpet manufacturers offer a semi-bespoke service, where a library design or custom pattern can be made in a combination of colours from a set, stock colour palette. These colours are permanently loomed, so no downtime is required to change colours.

Through the Ready to Weave programme, we have three looms permanently creeled with stock colour palettes, giving designers the opportunity to colour any library or custom pattern in up to 12 colours. Choosing from a stock set of colours, proven in commercial environments, provides designers with a unique carpet perfectly in keeping with their environment through a fast and efficient UK-based manufacturing process.

For this reason, Ready to Weave has grown in popularity thanks to its combination of flexibility, speed of manufacture and value. With a minimum order of just 100sq m, Ready to Weave is also readily accessible and can be delivered in as little as four weeks.

The right performance
Much of whether a project needs a tufted or woven carpet depends on the footfall requirements of the space. In fact, in any project there can be a demand for both constructions.

A natural hunting ground for broadloom carpet, hotels are a prime example of this: bedrooms and upper level corridors will be adequately catered for with tufted carpets, while areas such as bars, receptions and stairways will need the durability of woven carpet.

Again, in these areas woven carpet can be adapted in quality – an eight-row in libraries and lounges versus a 10-row in function rooms or reception – to ensure that affordability is maximised wherever possible.

Any good carpet manufacturer will be able to advise you on the best way to ensure the carpet you choose is right for the task at hand. Once an industry dominated by manufacturers only weaving carpets or only tufting carpets, most contemporary manufacturers can now supply tufted and woven carpet. However, it’s worth noting only a few continue to produce all carpet in the UK and even fewer that offer both constructions in the same wool-rich blend.

Wilton Carpets
01722 746000