How Are Carpet Tiles Made?

How are carpet tiles made?

How Are Carpet Tiles Made?

Most pieces of furniture, fittings, and fixtures are often mass-produced with a relatively uniform process that is adjusted for particular styles and results. However, the manufacturing of Carpet Tiles breaks this mould, figuratively and literally.

Even compared to traditional carpet rolls, Carpet Tiles are quite complex to make, in no small part because there needs to be a perfect match between the upper fabric material and the lower underlay material used to affix the tile to the floor.

Here is the process that takes the high-quality materials and uses them to make robust, reliable and effective Carpet Tiles.

Create The Carpet

The first few steps in the production of Carpet Tiles are the same for making any other carpet, whether that takes the form of traditional woven, knotted pile, tufted or any other mass-produced carpet creation technique.

This first step will determind the material that you need to stabilise the tile, given the smaller dimensions, with a carpet rolls of around 2m wide so that 50cm x 50cm and 100cm x 100cm tiles can be easily made with the same roll.

What A Beautiful Wedding

The next step to a high-quality tile is the affixing of a robust multi-layered backing to the carpet material, to ensure it has weight and stability, as well as protection against exposure to extreme heat and cold materials.

The first step is to evenly apply a fine bitumen adhesive layer, known as the 'wedding' layer, which is often achieved through the use of a roller system and a steady supply of liquid bitumen.

Melted Fibreglass Fabric Layer

After the bitumen layer has been laid, a fibreglass cover is loosely placed on the bitumen before a second layer of bitumen is applied which creates the stable spine of the Carpet Tile. After this, a cover fleece is laminated on, providing batch numbers and laying directions for the tile carpet.

In total, the back layer consists of the fibreglass cover fused between the two layers of bitumen glue, with a fleece cover attached to the underside. This is the overall makeup, but the exact nature of the different layers can vary depending on the material that is being used.

Certain softer piles need a lot more structural support on the underside, whilst harder piles can get away with less, and the particular use for the Carpet Tile can lead to different additional elements being added to the underside, such as rubber non-slip backing or waterproofing.

Cutting The Tiles

The final step is the cutting of the tile roll into the desired size and shape needed for each customer. This is usually controlled with laser technology and a rolling knife that cuts the webbing from below.

Typically this size and shape take the form of 50cm x 50cm squares, as this is the most popular type, but different shapes and sizes are available on request.

Finally, the tiles are packed into boxes, labelled and stored in a warehouse, ready to be shipped to customers across the country looking to replace their current tiles.

 

3 years ago
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