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3 Common Commercial Carpet Backing Types

Innovations in carpet backing systems over the last two decades have significantly advanced their functionality, durability, and performance. As a result, choosing the right carpet backing requires an understanding of various materials and their properties. Expert industry sources suggest considering the intended use, environmental impact, and specific characteristics of different backing types to make an informed decision.

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When specifying commercial carpets, understanding the backing options is crucial. Whether you're new to carpet specification or looking for reasons behind carpet failures, we've created this article to help. Our extensive experience at Mannington Commercial has been devoted to creating flooring solutions that meet high performance standards, including carpet backing.

In this article, we will delve into the various chemistries of carpet backing, explain the formulations of different backing systems, and examine the three primary types of carpet backing.

The Backing Process

The backing process typically involves applying an adhesive to the primary backing and often attaching a secondary backing. While some systems utilize single-layer secondary backings, multi-layer approaches are much more common. There are various techniques employed in this process, such as:

• The puddling method, where a viscous polymer is applied to the material.
• Extrusion, which forms a sheet onto the primary backing.
• Attaching a finished backing directly.

After application, the carpet is dried in an oven to eliminate moisture from the adhesive. If the carpet requires shearing, this is done post-drying but before the final manufacturing stages.

Why Is Carpet Backed?

Carpets are backed primarily to secure the tufts into the primary backing, enhancing the tuft bind, which measures the force needed to pull up a tuft. A higher tuft bind minimizes issues like edge raveling, zippering, and visible surface inconsistencies, while also increasing overall durability, aesthetic retention, dimensional stability, and moisture resistance.

Carpet Backing Chemistries

Carpet manufacturers generally utilize three main categories of backing systems: latex, polyurethanes, and thermoplastics. Each type possesses unique advantages and some challenges, tailored to different commercial carpet applications. Let's closely examine each category.

First Major Carpet Backing Type: Latex

The latex category encompasses several materials, including styrene butadiene rubber (SBR), vinyl acetate ethylene (VAE), and polyurethane dispersion (PUD). Latex serves as a cost-effective, industry-standard solution for broadloom carpets.

Advantages of Latex-Backed Carpet

Synthetic latex is highly versatile and generally outperforms natural latex across various applications. Key benefits of latex include increased adhesion, water resistance, and durability. SBR, in particular, is known for its strength and flexibility while providing excellent water resistance. Its properties make it installer-friendly and more affordable.

Disadvantages of Latex-Backed Carpet

Despite its advantages, SBR latex may degrade with age or when exposed frequently to moisture. Additional drawbacks include limited recyclability, a lack of warranties, and potential delamination issues. Latex also struggles in stress tests involving moisture impacts.

Second Major Carpet Backing Type: Polyurethane

The second category consists of polyurethanes, which are formed via reactive chemistry and have limited recyclability. Polyurethanes maintain their form once created, unlike latex.

Advantages of Polyurethane-Backed Carpet

Polyurethanes create robust materials with strong adhesion properties, ensuring that yarns remain closely woven, thereby enhancing tuft bind and overall carpet performance. They offer good moisture protection and edge-ravel resistance.

Disadvantages of Polyurethane-Backed Carpet

While offering robust warranties, polyurethane systems may incur higher installation costs and face challenges with delamination and seam welding, limiting their efficacy as a moisture barrier.

Third Major Carpet Backing Type: Thermoplastics

This category encompasses various thermoplastics, all of which provide dimensional stability and high strength against delamination and edge ravel. Thermoplastics can be divided into subgroups based on their heating and cooling properties.

Types of Thermoplastic-Backed Carpet

These backing systems typically use less material, leading to reduced shipping costs and easier installation. The recycling capability of thermoplastics enhances their environmental profile.

Hotmelt Backing Systems

Hotmelt systems are strong contenders with a higher tuft bind than latex but may pose difficulties during installation and become brittle in cold conditions.

Polyolefins

Utilizing an aqueous precoat, polyolefins are less sensitive to floor preparation, but their thin profile can reveal floor imperfections.

PVC

PVC backings resist edge ravel and can be chemically welded, providing excellent moisture barriers and aesthetics while being heavier and more expensive than latex options.

The Ins and Outs Of Carpet Backing

With many backing options available, understanding the distinctions among latex, polyurethane, and thermoplastic systems will empower you to make informed choices that contribute to your project’s success. Our goal is to deliver expert guidance, helping you navigate the complexities of these materials effectively.

If you're interested in further information or have specific inquiries about commercial carpet backing systems, we are here to assist with insights from our seasoned experts.

Related: How to Choose a Commercial Carpet Backing System

For those wishing to delve deeper into how to choose the right carpet backing systems, we've got additional resources available, including an accredited CEU session led by local sales representatives.

Don't hesitate to reach out for a consultation or to access our eBook that covers this topic extensively!