A few details
Langhorne’s expert weavers individually tend to all of our carpets from start to finish. Trained in the historic Langhorne tradition, they operate the broadloom much like a professional musician plays an instrument, crafting works of art worthy of the finest residences and halls in the world.
From our showroom to your home
When your selection is made, our technicians will come to your chosen location and take accurate measurements in the area(s) to be upgraded. Once you place your order, we take care of the materials and schedule an installation date that is good for you. We are punctual and strive to hand over your space in top notch condition. Your peace of mind is our goal.
When only the best materials will do
How It’s Made
There are basically three steps to manufacturing carpet. The first step is tufting. Tufting begins with the process of weaving the synthetic or staple fiber into a primary backing material. The primary backing material is usually made of woven polypropylene, and its main value is to provide a base cloth to hold the yarn in place while the tufting happens.
Now the carpet is taken through one of two dyeing processes.
The first method of dyeing is called yarn dyeing, or sometimes pre-dyeing, where the color is applied to the yarn prior to tufting. The advantages of all yarn dyeing methods include good side-by-side color consistency, large lot sizes, and uniformity.
The second method involves applying color to the yarn after the carpet has been tufted. This method is called carpet dyeing. There are several carpet dyeing methods in use, each producing a unique end result.
In the finishing process, a coating of latex is applied to both the tufted, dyed carpet’s primary backing, and also to secondary backing. Secondary backing is typically made of a woven synthetic polypropylene material.The two parts are squeezed together in a large heated press, where they are held firmly to preserve their shape. Shearing, one of the last stages in the manufacture of carpet, is the process of removing all of the little loose ends and projecting fibers that might have been created during the tufting process. It also helps achieve the yarn’s tip definition of the finished carpet.
Finally, each carpet is carefully inspected for color uniformity and other manufacturing defects before it is rolled, wrapped, and shipped.
Connect With Classic Floors!
Classic Floor Designs
2120 L ST NW
Washington, DC 20037
Saturday by appointment