I like Pottery Barn. They have some cool household items and furnishings, some of which are good quality at a good price.

Their rug department however, is a different story… and in the rug cleaning world the term “POTTERY BARN RUG” is becoming synonymous with “PROBLEM RUGS.”

First of all, Pottery Barn does carry some VERY nice woven rugs coming from Afghanistan in particular. They have some very decorative wool hand woven rugs in their Arzu line. I like that they are funding a craft that is allowing women in Afghanistan to make a living for themselves and helps support education in the region. The ARZU project is a production line to absolutely support.

As you recall, you determine if a rug is “woven” by whether  you can see the design on the back of the rug exactly as you see it on the front, like this:

Woven wool rug.

So the WOVEN rugs that Pottery Barn is selling are very good rugs. But that is just a fraction of what they sell today.

The problems are coming from their “other” rugs, in particular their TUFTED rugs and other specialty pieces using “natural” fibers.

Tufted rugs have a material on the back, like this:

Tufted rugs have canvas material on the back.

Whoever is running their TUFTED rug department (including their Pottery Barn Kids rugs), and their “earth friendly” rug department are choosing some of the most difficult, if not impossible, rugs to live with and maintain.

As a professional cleaner (or a consumer shopping for rugs), these are the ones to keep an eye out for to avoid… or be very careful with:

RUG TO RUN FROM => TUFTED RUGS FROM INDIA

We wash hundreds of rugs a week, so we see “flawed” product relatively quickly because we wash a whole host of natural and synthetic woven and tufted rugs.

Without a doubt, there is something seriously wrong with the tufted rugs coming out of India today, and in particular the lines being sold at Pottery Barn. These are the problems we are seeing on a consistent basis from TUFTED rugs from India:

1) “Burnt Rubber” Odor from the Latex

I’ve discussed this problem on this blog before, the strong pungent odor that comes from these India tufted rugs. The latex is either mixed with filler that has contaminants that off-gas over time, or the latex itself has soured before application. Both lead to a smell that is similar to a mix between burnt rubber or asphalt and stinky dirty socks.

It is AWFUL.  And it is NOT correctible to my knowledge.

And if you don’t want to just take my word for it, here is just one post where SCORES of people post their smelly horror stories with these problem India tufted rugs from Pottery Barn.

To Pottery Barn’s credit, as you can see in the thread over several years of posts, you see that there is an “easy” exchange process for those who want to replace their rugs for ones that do not smell (i.e. the rugs WITHOUT latex used in the construction).

What I do not understand is why with such a high volume of documented complaints on-line, why they would insist on carrying so many TUFTED rugs in their Kids selections. When you have kids crawling and playing on rugs, why would you let them breathe in those *bad* odors?

I keep seeing statements that the odors are not “harmful” – but isn’t the fact that something smells bad enough to get away from it mean your body’s warning system is telling you it’s *bad*?

The problem seems to get worse over time, and becomes more noticeable when rolled up for a time, or closed up in a room with no air circulation. It also becomes more apparent when it gets wet – which means if you ever spill on it, or need to have it cleaned, there will be an issue.

So, in the worst case situations, these rugs are not cleanable. (Why would you own a rug you cannot clean?)

Here’s an example of a backing of one of these types of problem tufted rugs:

Tufted rug. The material is covering up latex, and it smells.

Here’s the labels on the back:

Labels. "Natural rubber latex" tends to be the smelly culprit.

2) Delamination of the Latex

In the India Tufted rugs, we are also seeing today a lot of “filler” being used with the latex mixture that simply cannot hold up to age, being walked on, or moisture. The latex delaminates and crumbles and cracks. One of the reasons they cover it up with that material is because without it you would have a HORRIBLE mess on your floor.

Here’s an India Tufted rug that is delaminating:

Latex is crumbling.

Here’s another one:

Backing has fallen off and latex is crumbling away.

The problem with these inferior grade India Tufted rugs, besides the mess, is that when this latex crumbles away the rug loses both its shape and the fibers themselves. This means that if the owner wants to continue using this rug, the professional rug cleaners needs to wash the piece very carefully, remove as much *bad* latex and filler as possible from the back side, and then apply a new latex coating (without the filler powder) and a new material backing.

This type of repair is NOT inexpensive. So people who choose to buy a TUFTED rug because it’s a bit cheap than a WOVEN rug, will end up having to pay for a wash and a repair – so it ends up costing them more to care for that rug.

Tufted rugs also only last years, whereas woven rugs last for decades, if not a century or more (if woven well and properly cared for). So as with all things, if you pay a cheaper price for it… there is probably a reason why…

…and you will find out soon enough.

3) Discoloration and “Uglying” of the Backing Material

The canvas or linen or jute backing material is covering up ugly latex. When the rugs are spilled on, or when they are washed, this backing gets water marks, latex discoloration, and browning as a result. This is a common sight on the back of TUFTED rugs:

India Tufted rug. Backing gets discolored.

Sometimes the discolorations are some “yellowing” from the cotton/linen/jute used, and can be improved with some additional cleaning of the back:

Tufted rug from China - light yellowing.

But on the whole, if you own a TUFTED rug, and particularly the ones from India with the added filler in it, you will be getting a rug with a blotchy and marked backing after it is cleaned. The material can be replaced, but I find that most people when given a substantial repair estimate do not really care what the back of the rug looks like as long as it is clean and the front looks good. They understand that washing a rug like this, that cotton backing acts as a “filter” as latex, filler, soil, and water all flows through it.

4) Buckling of the Top Side and Shedding of Fibers

With TUFTED rugs, how “square” it is or isn’t is based on that latex and the material backing. So when it begins to delaminate, the shape of the rug gets lost. The top side get waves in it, Sometimes a few:

Waves on top side.

Sometimes A LOT:

Bad latex leads to lots of buckling in the rug.

Coinciding with the deterioration of the latex, as mentioned before, the tufts of wool can pull loose when there is no strong latex holding it in place. You might find full strands pulling away from the rug, or if the rug is made of inferior grade wool (sometimes in India this can come from being sheared from dead sheep), then it will break off and shed.

You will notice when you are on the Pottery Barn website they mention that “some” shedding is expected from wool rugs. This is true. Wool is spun with many short strands together, and then the rug is shaved after being crafted to have an even pile on the front, so yes, there will be some shedding.

However, better quality production will WASH a rug after it is woven to remove many of these loose short clippings. So “some” shedding should be very little. If you have a rug that is consistently shedding, and when you run your fingers across the face it breaks away with pressure or light pulling, then that is a PROBLEM rug. That is a sign of bad wool. which you often will find in TUFTED rugs that are at cheaper prices.

Wool is strong. It is literally the best fiber for use in rugs.

If you ever have a wool rug that feels brittle, or breaks easily, that is a bad sign. Either it was bad quality wool to begin with, or it has been so heavily chemically processed, that it has become weak. You want to run from rugs like these.

RUG TO RUN FROM => CHUNKY WOOL SHAG RUGS

I’m not sure why these rugs were created.  Our nickname for these rugs are noodle rugs, because they look like big noodles:

Noodle shag rug.

They are big chunks of wool strung into a material backing. Sometimes they have latex on the backing, and sometimes they are just loosely strung in, which makes them state that the rug is “woven” when I would not of course ever call these “hand woven” or “hand knotted” rugs.

Here’s the label:

Label says keep in a "well-ventilated area" ... which means it STINKS too!

If you see these rugs at first you might look kind of cool, especially in their variety of colors…

…but if you have ever owned a shaggy dog, then you will understand why these rugs are super tough to maintain and care for. The problem is, getting soil, lint, and general “fuzziness”  out of these fibers is as tough to do as combing out those spurs and knots are from your shaggy dog’s fur.

These rugs often require a great deal of extra hand work after cleaning to literally comb through row by row to try to “pull up” anything that was tangled up too much in that felted type of wool to wash away.

This means cleaning these rugs, even though they are not super expensive to buy, will often cost you more to do than if you had gotten that higher price woven rug.

This is one of those rugs that when you first see them, you think they are cool, and then you realize that it was a completely impractical choice for a floor covering and that you should have run from it.

RUG TO RUN FROM => “EARTH-FRIENDLY” PLANT FIBER RUGS

First of all, the MOST earth friendly rug you can own is a woven wool rug. Wool is a completely sustainable and renewable resource that grows back year after year.

But several stores are crafting rugs they deem as “earth friendly” from plant fibers and attempting to imply that these are also good rug choices. These rugs are made from SISAL, JUTE, and RAYON.

The problem with sisal and jute, besides the fact that they feel like wicker furniture instead of a soft rug fiber like wool, is that they both release oil when wet, yellow, and get brittle with age.

What is interesting is that on their website they state that sisal is “stain-resistant” when actually stains are quite difficult to remove from sisal. When a spill gets on it, and oils from the plant fibers release, it makes darker areas that can be tough to even out. And if the owner of the sisal rug has pets, and the spill is pet urine, the rug cannot be soaked to remove the contaminants because the cloth border binding may shrink, or the rubber/latex backing may  have structural problems.

To be safe with sisal, you need to use it in areas where you don’t feel there will ever be any spills, and no pets. And you just need to know that if you have a spill disaster on the rug, that you may have to replace the rug.

With jute, when it gets wet it likes to yellow and brown badly. For some strange reason, jute is being used as a foundation fiber on many of today’s lesser quality rugs. (I guess I answered the “strange reason” – it’s used because it’s cheap! LOL.)

Here’s a cotton rug with jute foundation warps that are creating yellowing in this rug:

When you wash these rugs, a cotton shampoo with an acid rinse can help lessen the browning of both the jute and the cotton, but over time this will become a more noticeable problem (especially if spills occur on the rug).

The problems with rayon/viscose rugs, which is used as artificial silk, are many that I’ve covered in depth on this blog. It bleeds and fades, it breaks, and it yellows.

These rugs all look great when they are brand new, and then they proceed on getting “less pretty” with time.  I know I keep hammering how woven rugs are the better choice, but that’s because after DECADES a good quality woven rug will still look like it did when new…

… but these plant fiber rugs begin to look worse in just a year. And if you spill on them, they look worse even faster.

Here is a Pottery Barn rug that has the TRIFECTA of tricky components: RAYON face fibers, JUTE foundation, and LATEX backing:

When this rug was new, it looked more like “silk” and was whiter. The fibers of rayon and jute, both of which yellow with moisture and age, are giving this rug a yellower look over time.

The label indicated the “fragile” strength of this rug in that it warns against many things: spills, sunlight, heavy furniture, and spot removers:

Warnings, warnings, warnings...

The owner did use some household spot removers on this rug, which due to the rayon did in fact make it lose what color it had in the fibers to begin with:

Sensible spotting led to bad results.

The fact is, if this rug had been wool this result would not have happened. It’s because the fibers are weak and sensitive that there was a problem.

(By the way – for safe spotting tips for spills on wool rugs, here are some safe rug care tips.)

You can see with this rug also, we have the LATEX factor, where a rug with any type of furniture on it is creating creasing problems in the backing construction itself.

Backing is not strong on plant fiber rugs.

Now, the person who bought this rug did so because she liked the look of it, and she believed that it was a quality piece because of the price she paid. She was not aware that the cloth binding material used would begin to buckle, that the backing latex would lose its flat shape, that the jute and rayon would begin to yellow, and that she would never be able to spill anything on the rug without it being a disaster to the way the rug looked.

With plant fibers it is sometimes possible to bleach out some problems, but this is extra work above and beyond regular cleaning, so it makes it more money to maintain this type of rug.

And that is what this all comes down to…

…EDUCATION.

The fact is, when consumers realize the differences between woven rugs and tufted rugs, or wool rugs and plant fiber rugs, and they are given the pros and cons of each, then they feel they can make educated buying decisions.

It’s when they buy a rug they like, and discover problems they were unaware of – strong odor, weak fibers, bad latex – that is when they feel they were sold bad goods. That’s when consumer feel ripped off…

…even if it was not a very expensive rug to begin with.

So now you know some of the common problem rugs being sold at Pottery Barn, and can choose whether to buy them or not – and if you are a cleaner, whether you want to clean them (or CAN clean them…) or not.

My hope is that there are enough complaints coming in about these specific rugs, that they are changing the rugs they carry. I don’t think any company likes to be knows for selling “rugs to run from.” And I know us rug cleaners don’t enjoy cleaning them. =)

Happy Rug Cleaning!

- Lisa

P.S. Just a heads-up that we are currently accepting applications for the 2012 Textile Pro Program, which is an advanced rug and fine fabric care training program by Jim Pemberton and myself. We are currently choosing the companies that we will be working with throughout 2012. If you think you might have what it takes to be a Textile Pro, then send an email with the subject RUG TRAINING to textilepros@gmail.com.  Merry Christmas & Happy New Year!

Most professional rug cleaners should know this, but in case you don’t…

… wool rugs with material on the back like this one, are called TUFTED rugs:

Tufted rug from China. Loose cotton material backing.

Some have a loosely attached material like the above one from China, and some have material that is more firmly in place like this one from India:

Tufted wool rug from India.

I call tufted rugs “fake rugs” because these are commodity rugs that are quickly constructed by punching tufts through a canvas backing, and covered in a great deal of latex adhesive to hold it together, and then they shear off the top loops so that it gives the illusion of a pile woven rug from the top side, when it’s not woven at all.

Woven rugs take months, sometimes years to weave. They are pieces of art.

Tufted rugs are a way to get the “look” of a real rug (to the untrained eye), at a fraction of the construction time and cost. Most are “commodity” rugs. These rugs take days to craft, as opposed to months, and they will last you several years of use as opposed to woven oriental rugs that often outlive several generations of owners.

So, as with anything where corners are being cut to create a faster, cheaper version, there are consequences. And especially consequences – and limitations – if you are cleaning these tufted rugs.

Regardless of the type of material on the back of tufted rugs, they are all covering up this ugly mess of latex on the back holding the tufts of wool in place:

Latex backing of a tufted rug.

It is much prettier when covered up with material, don’t you think? =)

We mentioned the “plus” of tufted rugs, which is primarily that they are crafted faster and as a result are much cheaper to buy versus woven rugs.

(There are some high-price exceptions like Edward Fields hand crafted tufted rugs, which are much higher quality than what I’m showing here, but that is 1% of the tufted rug market, so I am talking about what you are seeing coming out of China, India, U.S., and other countries today.)

Let’s talk about some of the “consequences” of choosing a commodity tufted wool rug instead of a woven wool rug, so you are not surprised when any of these challenges come up.

BUCKLING

If you take a tufted rug and place it on a soft surface (like putting it on top of wall-to-wall carpeting) and then set heavy furniture over it, you will be in for a surprise.

Tufted rug buckling from furniture.

Though a good amount of latex is used on the back of these rugs, it’s still susceptible to cracking when too much weight is focused on specific points. If there is not a durable pad under the rug to support the furniture, then these lumps in a rug like this may not be correctible.

Back of Chinese tufted rug.

These rugs, to keep their shape, need to be on top of a hard surface when used. These face fibers are not twisted around warps like woven rugs are, but rather are looped in the shape of a “U” – so the only thing holding them in place is a thin dollop of glue. Take a look at these fibers falling away from this torn corner of a tufted rug:

Tufts falling away from a damaged corner.

There really is not much there to hold those “U” fibers in place. In fact, even with brand new tufted rugs, if you grab one fiber and tug, you will be able to pull it out.

Because of this latex construction, you want to take care on what you place on top of it, even if the rug is brand new, because it can’t take too much weight and bending.

DELAMINATION

Over time latex will degrade and deteriorate. In the past this meant a bit of crumbling and cracking, but in some of today’s tufted rugs, delamination is a MUCH messier situation:

Backing deterioration from water exposure and inferior quality latex.

Some of the lesser quality tufted rugs, in particular some coming from India today (and also some US hooked rugs), are using latex mixed with “filler” to help extend the batch of the adhesive and also to provide a firmer application to give the rug some shape.

This filler is sometimes marble dust, and sometimes concrete. But it is always a MESS when it gets wet.

This is by far the biggest danger facing rug cleaners today in handling tufted rugs, is the fact that some of these rugs cannot be soaked without having to deal with a big ugly mess. The rug not only cracks, crumbles, and powders all across the back and often “poofing” up through the front also…

…but it also leads to the rug losing its shape, because it was that heavy latex and filler that was making the rug stiff and square in the first place:

Tufted rug lost its shape after the latex deteriorated from a flood.

If you need to wash the rug (because it’s quite dirty), pull off the material on a corner and see if you might be unleashing a disaster with getting the rug wet.

BACKING DISCOLORATION

What do you think happens when you have an ugly, messy latex application, and then place a nice clean cotton material backing over the top?

At first, it looks great. Then, over time it begins to yellow (wouldn’t you if you were laying up against glue 24/7?)…

…and then when you wash it, and the glue residue, soil, dyes, and other “unmentionables” go through that cotton, like a filter – what do you think that does to the cotton? Well, I’ll show you:

Water marks, dye marks, browning marks on the back of a clean tufted rug.

One of the unfortunate consequences of owning a tufted rug is that when it gets washed, that backing gets marks all over it.

If the tufted rug is not heavily soiled, then a cleaner may opt to surface clean it as best as he can, and not mark up the backing, but in most cases rugs that come in for cleaning need a good wash. And soaking these rugs, which gets them the cleanest, will change the look of the backing material.

Water marks and browning on backing material.

Some of these marks can be improved with additional cleaning on the back side with an upholstery tool, to try to remove some of the browning on the cotton material. It adds additional cleaning time, and cost for this, but many people often do not care what the back side of their rug looks like, as long as the top side is nice and clean.

If the additional cleaning time does not improve the backing enough for the owner, it is also an option to pay to replace the material backing with a new piece (sometimes that is easier than trying to carefully clean the back and strip out those discolorations).

STENCIL INK BLEED

Another problem that is sometimes uncovered in the lesser quality hand-tufted rugs is the use of stenciling ink (usually pink or blue) to mark where tufts are places, and this ink can wick out and bleed when wet.

Back of tufted rug - stencil ink bled into backing material.

If you are not careful when cleaning rugs with this type of manufacturing flaw, then washing the rug can wick that ink to the top side of the rug’s fibers, and create large ink stains, which can be difficult to remove.

It’s important to look for “clues” on the back side that indicate stenciling marks were used. You can also grin the front fibers and look for anything noticeable from the front side.

Stenciling can be a messy problem. If you see the ink in your inspection process, and it is heavy, and bleeds in your dye test, then you may opt to only surface clean the rug.

It’s not the most thorough cleaning process to surface clean it, but it will be the only safe option for you in that case, especially if you are not equipped with the right type of equipment to quickly remove the water from the tufted rug and dry it quickly.

DECONTAMINATION CHALLENGES

Decontaminating tufted rugs to remove pet urine odor, or to decontaminate from flood exposure, can be tough.

Repeated pet urine contamination on a tufted rug can be next to impossible to remove the stink. Think about it… urine penetrating heavy glue. Do you really think a quick cleaning can get the contaminants out of that adhesive?

Tufted rug - flood contaminated.

Whether the tufted rug was a pet toilet, or was involved in a flood, it needs to be fully soaked to wash and decontaminate. But, with the earlier problems mentioned, the longer you soak these rugs the more problems you have.

It’s a catch 22.

You need to soak it to remove the odor causing contaminants, but soaking it can contribute to delamination, yellowing, water marks and discoloration on the backing material, and possible stencil ink bleeding.

What’s a rug cleaner to do?!?

Communicate all of the dangers, and the options, and have the rug owner tell you what they want done. Just be sure if you go ahead with the wash that you have a release of liability in case the “worst case scenarios” unfold during the soaking. The cleaner should not be punished for limitations created by poor rug construction.

ODOR THAT IS NOT COMING OUT

On some tufted rugs, the odor will not be coming out no matter how long you soak the rug.

Tufted rug bad odor.

With a certain percentage of tufted rugs from India (including many of the problem India rugs being sold through Pottery Barn, at least in the San Diego area), the rugs have an awful odor present in brand new product.

The odor is a smell that is like a combination of burnt rubber and dirty sweaty socks. It’s rancid, and it gets WORSE with cleaning.

It appears to be situations where the latex has gone bad and soured, and they still use it anyway. This is a manufacturing flaw, and the rug should be returned for a problem-free one instead.

HOW TO HANDLE TUFTED RUGS:

If you own a tufted rug, and you’ve bought it from a reputable rug merchant, you will likely have no issues taking it to be professionally cleaned. Do not clean the rug yourself. These rugs take considerably longer to dry, and you open up yourself to a whole host of problems (and mess) if you try a D-I-Y clean.

These rugs also should never be cleaned in the home setting. Though there may be no warning signs on the rug itself, you open yourself up to potential damage to the floor underneath (yellowing, dye transfer, latex powder residue).

If you are a professional rug cleaner, these are the things you need to take into consideration, because today’s tufted rugs hold many more challenges than those from even a few years ago.

Your pre-wash inspection process needs to include front and back close evaluation, and grinning open the front tufts to look for stencil ink dangers. Give the back of the rug a whack and see if any powder POOFS out to the front, especially in areas where you see there have been spills on the rug. This will show you delamination dangers if you are unable to pull away the backing material to evaluate the strength of the latex.

Tufted hooked rug. Latex back.

It is always best to communicate expectations BEFORE the wash. Share how the rug is constructed, and why it has material covering up the back, and that this will get blotchy after cleaning.

It is possible, when rugs delaminate, to re-latex the back and put a new material backing on the rug. This takes time and adds a significant repair cost to the cleaning. But if the rug has gotten heavily soiled, or contaminated by pets or a flood, it may be necessary to fully wash and then fully repair the rug in this way.

And the work may end up approaching what they paid to purchase their rug to begin with, so you might give them the opportunity to buy another rug instead. Especially if there is a chance that the odor in the rug won’t be coming out of that glue. Unfortunately some of these rugs end up being “disposable rugs” when they get contaminated badly with pet urine, because getting the odor out can be tough.

When corners get cut to produce a product that is cheaper for the buyer – someone ALWAYS ends up paying.

I just wanted to point out some of the dangers lurking in some of these tufted rugs so professional cleaners don’t end up being the ones who end up paying. =)

If you are thorough with your pre-inspection process, you will see the warning signs to keep you on safer ground.

Happy rug cleaning!

- Lisa

P.S. Those of you anywhere near Fort Myers, Florida – I’m teaching an afternoon class at Excel Supply on Wednesday, November 9th. I rarely make it down south so come learn some valuable rug basics, and bring all the questions you have about this business and how to be the best at it. Sign up by calling 1-800-909-3590. See you there!

I just had the privilege of speaking to a group of CFI members up in the Inland Empire. (That is the Carpet & Fabricare Institute, which is a professional trade association that covers cleaning and restoration professionals throughout California, Nevada, and Arizona.)

The topic was… I know you’re shocked… RUGS! =)

After several hours of non-stop teaching on my end, I promised the group I’d make a post to link to a number of posts here that covers some of the topics we talked about more in depth. So here’s the list!

CLICK HERE => Rug Shop Set-ups

CLICK HERE => Rugs and Pets

CLICK HERE => Rugs That Bleed

CLICK HERE => Rugs and Plants

CLICK HERE => Tea Wash Rugs

CLICK HERE => Why Some Rugs Buckle

CLICK HERE => Why Rugs Aren’t Cleaned In The Home

CLICK HERE => Rugs and Floods

CLICK HERE => Silk Rugs

CLICK HERE => Fake Silk (Viscose) Rugs

I’ve been a member of CFI for several decades, and I’ve met some of my closest industry friends – and best mentors – through this group. I served on their board for 11 years, a few of those as president, which was a highlight for me… even with all the “battles” we had in those good ol’ days – LOL!

It has been exciting to see the energy, creativity, and passion behind those on the board right now… and I’m looking forward to seeing what they have in store for the group and all of us members.

Thank you CFI – and thanks to Jason and Terrance for inviting me to come meet their members. I enjoyed it!

- Lisa

P.S. If you are a professional cleaner and do not have a trade association that you belong to, it’s worth taking a look at CFI. Their number is 1-800-CARPET-9 if you want to call to see about upcoming meetings and educational courses.

I receive a lot of “help me” calls from rug cleaners and rug owners on rugs that are buckling. They want to know what to do.

And my answer is usually… it depends.

That’s because there are a number of reasons why a rug is buckling on someone. Some of these reasons are correctable. Others are not.

Here is the list of different causes of buckling:

Weaving Characteristics

No hand woven rug is perfectly symmetrical. There will always be a little bit of variance in the width and length, and some fluctuation in the weaving tension throughout the rug itself.

A city rug (woven in rug factories in weaving cities) will of course have more quality control than rugs woven by tribal weavers. I personally prefer the tribal rugs because they have more character and personality.

Weaver using a horizontal loom.

That said, in some tribal weaving centers, especially in areas that are war-torn like Afghanistan, the consistency can vary beyond being an interesting weaving characteristic to being seen as a weaving flaw in some extreme cases:

Tension along end of this Afghan rug causes buckling.

Buckling from weaving tension changes, or width or length variations, are not unique to Afghanistan. You see examples of this in all weaving countries. And in most cases they are seen as unique characteristics of a rug’s personality. Like a few great laugh lines on a smiling face, or dimples, they are what make the rug have character.

And as with those lines or dimples, you can’t just take a steam iron and make those go away. There is no “Rug Botox” to use.

Sometimes a weaver – especially if the loom is a nomadic one – will not know the rug has a “buckling” problem until after it is completed and cut off the loom. In some cases a rug manufacturer will apply a sizing to the rug (similar to starch) to try to make the rug stiffer than it would naturally be.

The problem with sizing is that it will wash out, and it may be difficult to have it re-applied. So if you are buying a rug, or you are getting ready to clean a rug, you want to look closely at the shape of the rug and if you see any evidence of problems on the BACK side.

Creases can be clearly seen on the back of this Afghan rug. These are causing buckling on the front.

Sometimes a rug can be stretched to help it lay flatter, but this is a strenuous process that may damage the rug.

Stretching an Afghan rug to help it lay flatter.

In these cases you need to think about weaving variations as no different than one of your feet being a bit larger than the other. Think of what you would need to do to try to make them perfectly equal, and then apply that though to a rug, on the work that would be needed to make a side that may be an inch longer than the opposite one even.

It is often impossible to do. So your expectations need to be realistic, and if the variations are too much, then pass on purchasing the rug.

Material Backings

With embroidery, needlepoint, and hooked rugs, the buckling is often due to the construction especially if that construction includes a heavy material backing.

Embroidery needlepoint rug with a heavy cotton backing.

This type of weaving, though often very elegant, can also often not be perfectly symmetrical. And when you have two independent pieces – the hand crafted needlework and the material backing – that are loosely stitch to one another, this can create some buckling and waves.

Crewel stitch (aka chainstitch) needlepoint with material backing.

Hand crafted custom rugs using different fabrics and fibers can also lead to buckling, especially along the seams of there the pieces are put together.

Seam tape can split and buckle.

Seam tape can split under foot traffic, or with age, or from cleaning (especially if the individual piece are made of different fibers and may react differently during the cleaning process. Some fibers swell when wet, others condense. Some are stronger when wet, others are weaker. Some absorb more moisture and dry slowly, others dry quick. And these variances can split a seam if you are not careful.

Tufted Rugs (Latexed Material Backing)

Tufted rugs are the rugs you see with latex holding it together. Latex over time deteriorates and crumbles away, so often it is covered up with material to hide this kind of ugliness:

Old latex delaminating on a tufted rug.

Rugs are meant to be on a HARD floor, and not over soft wall-to-wall carpet. But, sometimes a soft floor is your only option.

While woven rugs (rugs you can see the design on the back of the rug same as the front) have some “give” to flex when over a soft floor, a tufted rug is not so forgiving.

Heavy furniture on top of a rug that is over a carpeted floor can stretch the fibers of a woven rug, and in worst cases create tears and holes. And with tufted rugs, which have a latex backing holding them together, they can create waves in the rug you won’t be able to get out.

Buckling in a tufted rug from furniture.

With these rugs, once they have been stretched from heavy furniture, and the latex backing cracks and bends, it’s damaged and will be very difficult to make flat again. It’s like when an elastic band gets over stretched, you can’t get it back to its original shape.

With woven rugs, you have a better chance of washing and reshaping a rug that has gotten buckles from furniture. And to protect BOTH types of rugs, short of putting them on top of a hard floor instead, you can seek out a stiff pad to place between the rug and the carpeted floor.

If your rug is tending to want to move and buckle even when it’s on a hard floor, then often a good rug pad will keep you from having any safety risks of people tripping on it. (Plus pads are “shock absorbers” for rugs and keep them from wearing from foot traffic as fast, and they also tend to deter bugs from wanting to find a home under your wool rugs. I personally love Durahold pad for rugs on hard floors.)

Edge Finishes (By Machine or By Hand)

Sometimes the ends or sides of a rug are finished a bit too tightly, or overdone, and this can create curling of a rug.

Heavy side cord wrap by hand on this dhurrie rug makes the corners curl up.

Machine serging of edges created curling of this rug.

The curling may be immediate, or only evident when the rug gets wet or damp. The level of buckling depends on how the fibers react to water. Some fibers get tighter when wet, and loosen when dry. This is especially evident on oriental rugs that are tightly woven, and the cotton foundation fibers tighten up when wet. (Think about your clothes when you take them out of the washer. Your cotton items are smaller and tighter, and your wool items are looser and stretchy. Most woven rugs are wool face fibers twisted around cotton foundation warps and wefts, so “wet” they can create some buckling that will go away when dry.)

Side curls on this damp Sarouk rug that is drying face down.

Leather or vinyl strips are sometimes sewn along the sides to help keep them flat on the floor.

If a hand woven wool rug is perfectly flat when dry, but curls when it is wet, then it will regain it’s proper shape when dry. Don’t panic.

An exception is Navajo and other American Indian weavings. Often the outside wrapping threads are not pre-washed before being used in the final weaving, and these strands may shrink a bit during cleaning, which can give the illusion that the overall rug has shrunk, when it is in reality just the outside cords.

Navajo rug from a flood, the outside cords have shrunk creating a buckling of the rug.

On the very first cleaning of a Navajo rug, the outside cord will need to be adjusted to make up for the shrinking of the cords, and future washes will not be a problem as far as buckling. (There are other concerns when handling American Indian textiles, from potential dye migration to wool fuzzing, that require an expert’s touch when cleaning. These rugs can be quite valuable, so always seek out someone with expertise in handling these pieces, as well as any investment textile or rug.)

Floods and Extraction Equipment

When rugs are exposed to flood water for extended periods of time, buckling can result from the absorption of the water in the cotton foundation fibers. In most cases, this buckling will be correctable. Though you need to follow the right steps to make sure you thoroughly clean and decontaminate any rugs exposed to flood waters.  Click here => for tips on handling rugs from floods.

Heavy extraction equipment (Rover and Xtreme Extractor) though excellent at pulling out the water, can sometimes create some buckling on looser woven rugs that may or may not be correctable. Whether it’s this type of equipment, or other extracting wands, it is better on the rug to extract from the BACK of the rug to try to avoid any marks or buckles from equipment. When using a wand it can help to have someone stand on the edge you are extracting to help hold the rug flat while doing the work.

Most rug cleaning facilities have roller or spinner wringers to remove water, which removes the buckling risk. Especially with the rollers, which tend to flatten out the rug smoothly for the drying process. But if extraction is your water removal method, you just want to make sure you are not too aggressive in this step.

Buckling in field of a rug from extracting.

Hanging Rugs To Dry

There are a couple negatives to hanging rugs up to dry if you do not have a professional climate controlled drying tower like the large rug washing plants have.

Hanging up a rather wet rug can bleed the dyes into the fringe. It can also create browning and discoloring of the fringe.

It can also, from the weight of the water, create a creasing of the rug that is difficult to remove, especially if the rug is tufted.

Some ways to lessen the risks are to try to get as much water out of the rug before hanging. If you do not have large water removal equipment, you can use a Water Claw in addition to your portable or truck mount wand to boost your extracting. The Rover, with its teflon head is excellent at removing water from heftier rugs without leaving any marks (even if you have to extract from the front side). Just make sure the rug is not too fragile.

Instead of hanging rugs on narrow planks, you can place a PVC pipe around the planks so that you can have it curved enough to help prevent creasing. You can also hang the rugs at at angle so there will not be a clean line of where the rug was bent to hang, like this:

Hang rugs at an angel to lessen potential creasing.

We dry our rugs out flat to avoid these risks, but most rug cleaning companies do not have the space to do this. So this helps if you have a mini-rack system that you are using.

* * *

These are the most common reasons behind rug buckling, and the situations where something can be done about it… or can’t.

Happy rug cleaning!

Lisa

P.S. I’m super excited because I’m finally ready to announce my return to the “rug training circuit” with a program that will be the best educational experience in our industry for crafting experts in the field of rug care. If you love rugs, and want to learn directly from me, then make sure I have your name on my Rug Chick list by entering your name and email in the “Rug Disasters Report Request” box up in the top right corner of this website. I’ll be picking a small number of companies in the coming weeks from my list to work with this year, so if you are interested in getting serious about rug cleaning, plug your name in up top! =)

Rugs are loosely lumped into two general categories – “tribal” rugs or “city” rugs.

City rugs come from “bigger” weaving operations that tend to produce rugs with more intricate designs, higher knot counts, and tighter quality control. This is a broad generalization of course.

Tribal rugs come from smaller operations, or nomadic weavers who weave as they travel. They tend to have designs that are a bit cruder, with sharper edges instead of curvilinear designs. (FYI – in a future post I will explain why you see this curvilinear versus geometric difference, it’s related to the warp and weft construction and knot type.)

I’ve seen many beautiful “city” rugs in my lifetime…

Beautiful silk "city" production rug.

…elaborate designs, vivid colors, and a fine weave that makes them almost perfectly symmetrical.

Very finely woven Turkish Hereke silk rug.

Though I have a real appreciation for the “city design” pieces…

…when it comes right down to it, I like the tribal pieces more!

They are cruder at times, usually utilizing weaving techniques that make them have more of an “etch-a-sketch” type design than the beautiful floral illustrations shown up above…

…but I like the more geometric – and strong – style.

Great old Kazak (woven in Caucasus Mountain region)

I just love the tribal design pieces. To me they have more “character” and personality. If they are made with natural (“vegetal”) dyes they are very vibrant, with a lot of texture and depth to their look. And the older ones have such a fantastic luster to them.

I mean, just LOOK at this incredible piece here:

Gorgeous old Afshar rug.

Whether they are rugs from the Caucasus region, the Persian tribal weaving regions, the Baluchi tribal pieces, the Tibetan and Nepalese pieces, or even American Indian weavings – I am drawn to these typically smaller, cruder, but much more “energetic and alive” (to me) textiles.

I really feel like these are a piece of someone’s life – and heart – that now has become part of my life. Old textiles become new friends of those who love rugs.

That said – just like with “real” friends – there are some “personality quirks” that can come along for the ride.

“Oh your rug has a GREAT personality!” (aka the “quirks” are charming…)

Quirks, which in newer rugs – in particular coming from Afghanistan – can result in some trade-off’s that might unsettle those who are looking for a perfectly designed rug.

This is especially due to two factors in that region, one being the war’s impact on resources and consistent commerce, and another being their “tradition” of weaving wool on wool rugs (versus wool woven on a cotton foundation).

Of course, before cotton became “king” wool rugs were all woven on wool warps and wefts. The use of cotton allowed for the creation of larger, flatter, more symmetrical rugs because the cotton can be spun into smoother stronger strands for use as warps and wefts versus wool which when spun has more variation in thick and thin areas.

Hand spun Merino wool varies in thickness.

Wool is an exceptional fiber, in fact, the best rugs to buy today are wool rugs, in my opinion. They are super durable, can be vibrantly dyed, are naturally fire-resistant, and are the truly renewable resource (grows back year after year on sheep).

Where the wool face fibers can be sheared to create an evenly piled rug, when you are using wool as the warps and wefts of a rug – the “skeleton” of the rug – there are “quirks” that come about in the form of unevenness, buckling, creases, and sometimes shrinking if the wool had not been thoroughly washed and scoured before being spun.

In the industrialized countries wool processing and scouring is a serious operation, which cannot be duplicated as consistently and “aggressively” in tribal areas…

…especially war-torn tribal areas like Afghanistan.

So the trade-off for an authentic tribal piece from this region will be some quirks like these:

An uneven shape. Perfectly symmetrical is NOT an option.

On smaller rugs, the tribal characteristics are “cute.” If the rug is a few inches wider along one end than the other, it’s not a big deal. But when LARGER rugs are woven with that same varying tension and technique, the “quirks” can become more of a distraction than charming.

Creases in the weave seen on the back. This can make the top side have small "waves."

Uneven tension along the end created a big buckling problem.

Also due to the lack of the aggressive rinsing/scouring you can see an additional “quirk” of excess dye in the wool that can migrate (“bleed”) when the rug gets wet.

Afghan rug in a flood - red bled into the fringe.

Dye test shows this rug is not colorfast. A tricky wash that requires a rug pro.

Some buyers of tribal rugs want to make them “perfect” – but that is not unlike being born with one foot a bit bigger than the other (we all have one!) and expecting someone to “fix” that for you.

The variations with your friends, from size to freckles to goofy smile, is what give them their unique – and PERFECT – personality.

It’s not different with rugs. The tribal ones have more “character.” And just as with people, it is REALLY hard to “change” who you are.  It’s equally very difficult to undo the natural characteristics of rugs.

An attempt to STRETCH an uneven Afghan rug more flat.

Aggressively trying to "undo" weaving flaws that made the rug buckle.

Afghan Tribal Rugs: What to remember.

When looking at Afghan rugs, whether to inspect for cleaning, or to inspect for buying, just a few things to remember.

- Any visible “quirks” – such as buckling, creasing, curling – will become more prominent with its first cleaning. (If the rug has been washed in the past, then this will not be a problem if the rug cleaner is properly trained.)

- Any strong dye migration that transfers with the dye test means that the wool used in the production was not thoroughly washed prior to production, so if the rug is woven on wool warps and wefts, you need to expect more unevenness due to stretching or shrinking over time. If it’s a small rug you may not notice, because the tension will be fairly even. But larger pieces, having used multiple weavers over a much longer time, may result in a rug that is not as smooth to the floor as you’d like (if you are purchasing).

Afghan rug weaving project for women.

There are some beautiful rugs coming out of Afghanistan today. A few are highlighted on Emmett Eiland’s website on contemporary rugs. There are also several important weaving projects in the region empowering locals with a livelihood that I personally like to support.

But just as when a friend gives you some pottery she has made for you, and it’s not perfect, but you love it anyway – I look past any of the quirks in anything hand crafted that I get to have come into my life.

I’m not suggesting that all Afghan tribal rugs have some of these extreme “quirks” I have shown in this post’s photos. What I am saying is that ALL OF THEM will have variations in shape and size. Without a doubt, none will be perfectly rectangular, and none will lay perfectly flat on the floor.

The weaving of wool on wool will make these particular pieces prone to buckling, creasing, and more so when initially cleaned. Most times this will be very slight. The severe times will be evident at the time of purchase. You will see warning signs beforehand. None of these examples I shared here were “problems” that creeped up over time. The flaws were evident to begin with to a trained eye.

If you have a keen eye – as a buyer or a cleaner – you can avoid being surprised by inspecting the front and back sides carefully.

And if you are an owner of an Afghan rug, make sure you use a professional for the cleaning, because a D-I-Y cleaning on new tribal rugs might make your new purchase a ruined one if you are not careful.

I do not expect tribal rugs to be perfect. That’s what makes them “perfect” to me.  I like quirks!

- Lisa

P.S. With the holidays coming, make sure you know what to do when an unexpected spill happens. Print out the Holiday Rug Care Tips to have handy! (Merry Christmas!)

Most women have at sometime in their childhood tried a little needlepoint. (Perhaps some men also, but I can only speak for the “girls” I know right now.)

You have a little round frame that segments and holds tight a section taut of the cotton mesh (with a design imprinted on it) so you can do a series of stitches. It is almost color-by-numbers, where you use wool to stitch your little piece of art.

If you remember, it did not lay perfectly flat when you were done. Most of the times you made it into a pillow to help smooth this unevenness out.  Or perhaps you framed it.  If it was small this might not have been very noticeable, but as you tackled larger pieces it was trickier to keep the tension even in your stitching. A natural characteristic of a hand made product, the tension is never even.

There are needlepoint rugs on the market. Some quite large. Some done by hand, and some by machine, and they bring with it their own unique characteristics and a few “challenges.” 

Needlepoint rug from China

This is a typical new needlepoint rug. Attractive design. Nice colors.

Do you notice though, that it is a little uneven along the edges? That if you were to lay it out and measure it, that there would be some differences in the width and length?

Let’s take a closer look:

Front corner of the needlepoint rug.

Back corner of the same rug.

See along the edges of this rug, that even before its very first wash, when it is BRAND new, there is some buckling along the edges.  Just like with your little needlepoint pillow way back when.

Can you also see the stitching, and how there needs to be some colors tied off, and some areas doubled-over, so that it does not give the rug a completely smooth back?

Characteristics like these lead to a couple must-knows about needlepoints.

They are rarely perfectly stragith or symmetrical.

They rarely lay flat on a floor.

They are easy to kick up the edges if they are over wall-to-wall carpet.

They are easy to slide on if they are on a hard floor.

If you are cleaning them – there is a danger of some buckling of the cotton or synthetic mesh if you are not careful on its first cleaning. (If you are a professional rug cleaner with a facility, you have two options here: 1) Give the rug a bath and tack it out on a stretching floor during the dry time, or 2) tack the rug onto a floor BEFORE cleaning and clean it with a hand tool as you would tricky upholstery.)

Though I have seen some gorgeous needlepoint rugs in my lifetime, I tend to prefer these and tapestries up on a wall displayed rather than on the floor. And because of the thin structure of these rugs, laying them over wall-to-wall carpeting and placing any furniture on top of them would be a rug DISASTER. You will tear the foundation over time, as rugs are meant to be on hard floors, and with a solid pad underneath them.

When hanging rugs, I prefer having a strip of velcro attached to the back BY HAND … I’ll post some photos of this in my next blog post so you can see what I mean exactly.

If you own some great needlepoint rugs, or tapestries, you could consider putting them on display on your walls. (If you have some great old rugs, but also have some great old dogs in your home, you can save your rugs by mounting them on the walls also – nothing damages rugs more than pet urine.)

Just a few pointers on needlepoints, hope they help!

- Lisa

Rugs do shrink.  Some slight – a fraction of an inch … some a lot – inches. Usually on their very first wash IF they have not been washed after being woven (good rug manufacturers generally wash their rugs after weaving is done).

How much will they shrink? This depends.  You have to think about it as you would brand new clothing, that first wash will make it a bit smaller, but if you do a gentle cool clean, and easy dry, it’s less shrinking than if you hot water and hot dry the piece.

But with a woven rug, any shrinking will be slight.  (FYI – a WOVEN rug is a rug that you can see the design on the back that matches the front.)

There is an exception to the “slight” rule though … and this is tribal rugs woven on a WOOL foundation, and in particular Afghan wool on wool rugs.  Like this:

Corner of an Afghan rug - wool knots wrapped around wool foundation.

With this rug, the wool face fibers are wrapped around wool warps and wefts as opposed to cotton warps and wefts.

Cotton is generally the foundation fiber of choice, because it provides a consistent twist throughout, and helps create a rug that will lay flatter in the floor.  Wool, has a lot of give to it.  Just think of  a wool sweater, and how you can stretch it when you need to, or it can sometimes shrink up a bit.  It does not keep it’s consistent shape as cotton would when laid out wet to dry.

Because of the war-torn conditions of Afghanistan, for decades there have been rugs not necessarily created under ideal quality control conditions. And this can lead to some of the rug product in contemporary Afghanistan to shrink more than would be deemed acceptable.

I actually had the owner of an Afghan restaurant try to convince me that washing a rug should never happen because it damages rugs. I had to correct him that rugs properly woven with quality fibers, dyes, and construction can be washed throughout its 100 or more years and not have damage from cleaning. (Honestly, NOT cleaning it and leaving abrasive dirt in the fibers will cut the face fibers and cause more damage that way. Cleaning is the best thing you can do for your rug because it removes this grit.)

With some Afghani rugs, however, a wash can mean a release of dyes not properly rinsed before being woven into a rug, and it can mean some buckling and shrinking or stretching of wool fibers with different tensions and twists.

Luckily for you, the worst of the possible dangerous rugs to clean from this region will show you warning signs. Sometimes slight, like this one where the edges and ends show definite variations in width and length:

Rug is NOT symmetrical - wavy along all edges.

Sometimes the warning signs are so strong – you need to make the decision to only surface clean the rug because immersing it in a bath will risk making the rug shape even worse.  This rug is an enormous “don’t wash me” sign:

End is buckled from a poorly executed weave, and it will get worse with a wash.

With rugs like these, you do need to get a release of liability if the owner insists on having it cleaned. Photo documentation that this rug was NEVER perfectly square, and never laid flat on the floor, would also be helpful.

Sometimes these rugs can be stretched to a certain extent on a stretching floor to help loosen up the shape.  You can also tack out the rug and clean with a hand tool so that you can control the potential of shrinking.  However, these problems are WEAVING characteristics and not the result of improper cleaning.  There is literally only so much you can do.  You cannot undo a bad weave, or inconsistent tension.  All you can do is try to control the shape so that it does not become worse when cleaning.

The key here is to closely inspect the rug, and catch the warning signs BEFORE you clean the rug. Point out the characteristics of the rug to the client.  (Everyone repeat after me!) When it is communicated before the wash, it is EDUCATION – when it is communicated after the wash, it is an EXCUSE.

Rugs from contemporary Afghanistan can be a wash challenge.  Just keep an eye out for the signs.

- Lisa

Here’s a secret for you… ALL handmade rugs are crooked. Some may aim for perfection, but it’s very hard to achieve when hand crafting anything.

Have you ever written in a journal, set it down then picked it up to write again? When you go back you can see slight variations in your handwriting. The slant is a little off. Maybe you were more attentive and sharp, and other times sleepy – and the words showed those variations.

Weaving is not much different. Rugs are woven over months, sometimes years, and larger rug by more than one weaver – so there are variations that show up on the rug.  Like this:

Hah! Crooked!

When you inspect a hand woven rug you need to expect to find variations in the width and length of the rug. It is to be expected.  It is part of the rug’s “personality” – just like one of your feet is a bit bigger than the other one (go ahead, check).

But, if you clean a rug and place it down in the opposite direction, and the rug looks different to the client, they may feel that you’ve done something to shrink or stretch their rug.

It’s best to explain the variations up front, not as flaws but as characteristics.  Again, if you point it out BEFORE the wash it’s EDUCATION – you point it out after the wash it’s an EXCUSE.

All rugs are crooked. Nothing wrong with that!

- Lisa