Choosing a resource efficient carpet is especially important given the huge amount of carpeting used in the United States, and its relatively short expected useful lifetime. The Carpet Recycling Committee says that 1.8 million tons of rugs and carpets are sent to landfills each year. Major carpet manufacturers are reacting to increasing landfill costs and regulations and are now seeing a market advantage to improving the environmental impacts of their operations. These improvements have ranged from refurbishing used carpet to making new products from old carpet and carpet scraps, such as carpet fiber, carpet backing, soil amendments, auto parts and flooring materials. Companies that traditionally use nylon face fiber are now offering carpet with either post-industrial or a combination of post-industrial and post-consumer content. Some of these companies are also offering backing made from 100% reclaimed carpet. Almost all used carpet can be recycled into new products, although recycling PET carpet is not common yet. Reclaiming face fibers is difficult; most lines of carpet have one-of-a-kind formulations and identifying the components of used carpet is not easy. In addition, carpet is often contaminated and hard to collect and process. Even with these barriers, carpet is being reclaimed through carpet reuse, chemical recycling and mechanical recycling.

The vast amount of carpet manufactured and installed in the US is made of synthetic materials - nylon 6, nylon 6.6, polyester, and polypropylene (PP) face fibers with most backings being a sandwich of polypropylene fabric and latex, or poly-vinyl. Most of the commercial carpets are made by bonding a face fiber to a backing fiber, using one of a variety of strong bonding agents. Nylon 6 and nylon 6.6 account for nearly two-thirds of the face fiber market, with PP being the next most commonly used fiber. Nylon 6.6 has a higher performance rating than nylon 6 but it may not be enough to make a difference in selection.

Recycled content and recyclable carpet options each has its own merits and considerations, depending on your specific need, location, and use.Nylon, polyester, and plastics are made from petroleum, a nonrenewable resource. Since the face fiber backing can contribute up to 60% of the carpet material, purchasing a nylon face fiber with 100% recycled content backing is worth consideration. Closed-loop systems, where used carpet fiber and backing is made into new carpet and backing - and which can be recycled into new carpet after its useful life - is important to strive for. Leasing is another option for commercial applications; the manufacturer bears responsibility for replacing worn sections of carpet and recycling the used carpet.

Purchasing environmentally responsible carpet will include face fiber of some recycled post-industrial or post-consumer content (no one produces a 100% recycled nylon content fiber which is recyclable into new carpet fiber yet) with 100% recycled content backing, which in combination is recyclable. Or, 100% recycled PET polyester - which is now difficult to recycle after its useful life but in a few years should be. Most of the recycled nylon comes from post-industrial fiber (waste from extrusion and yarn mills, clean lint and edge trim from finishing lines) as opposed to post-consumer (carpet that has served its useful life). The technology is rapidly advancing (ie., DuPont and Shaw) to separate and convert used nylon fiber into new carpet fiber and backing, making a closed-loop system. As experience levels increase and manufacturing plants adapt their facilities to meet the new technology, the percent content of post-consumer content will increase. Several companies make carpet cushion materials that utilize recycled and natural materials such as recycled post-industrial fibers, recycled polyurethane, and jute and hair. Recycled tire rubber and recycled textiles and foam are made into carpet pad.

Keep in mind the following when deciding on a new carpet: recycling your old carpet so that it does not end up in the landfill, using carpet tiles rather than rolls to aid in spot replacement and longer life, deciding on the type of fiber (nylon, polyester PET, wool) and the recycled content and recyclability of the face fiber, backing, and cushion, the density and durability of the fiber for heavy traffic use, and how color and pattern contributes to wear. Some people prefer the appearance and durability of nylon over polyester, others will state that recycled polyester (PET plastic) is more durable and naturally stain resistant. Wool carpet is naturally flame resistant, durable, and provides excellent indoor environmental quality. Floor coverings other than carpet make good environmental choices.

CPG (Comprehensive Procurement Guidelines) Federal requirements:

Under the Comprehensive Procurement Guidelines, federal agencies are required to purchase items containing recovered materials (pursuant to EO 12783 and RCRA). Thirty-six items and 19 pending are currently listed; carpet is identified as one of these items. The recommended recovered material content for polyester face fiber is listed as 25-100% PET resin (recycled plastic soda bottles). Envirotech (Image) and Envirolon (Talisman) lines meet this standard. EPA is expanding it’s definition of environmentally preferred carpet by including nylon fiber with recycled-content backing (ie., Collins and Aikman, Shaw, Interface). These new standards will soon be reflected in the CPGs. For more information on carpet manufacturers and suppliers and a GSA link, visit EPA’s web site:

http://www.epa.gov/epaoswer/non-hw/procure/products/carpet.htm

Air Quality and Carpet Installation:

Check to ensure that your new carpet meets indoor air quality standards. Carpet can be a major source of indoor air contamination, although some tests show that carpet is one of the lowest emitters of VOCs among various interior products. The styrene butadiene latex rubber used to adhere face fibers to backing materials and the adhesives used to install carpets generate volatile organic compounds (VOCs). Carpets also cover large surfaces within an interior environment and can provide "sinks" for the absorption of VOCs from other sources. Carpets should never be installed near entrance doors or areas where moisture and organic matter can contaminate them. Carpet fibers are an excellent medium for dust mites and microbial agents, especially if the carpet becomes wet and cannot be properly dried. If installing carpet with VOCs, make sure that the carpet carries the CRI Indoor Air Quality Carpet Testing Green label. Installing carpets in strict accordance with the Carpet and Rug Institute guidelines as well as additional measures such as requiring suppliers to unroll and air-out carpets in the warehouse before bringing them into the building will minimize the risks of indoor air quality problems resulting from the carpet. Tests indicate that carpet emissions will dissipate within 48 to 72 hours with proper ventilation.

Alternatives to commercial carpets installed in rolls with adhesives containing VOCs include carpet tiles with tackless installation. Carpet tiles allow for the replacement of individual tiles when they are soiled or damaged. Fusion-bonded carpets use heat instead of adhesives to bond the face fiber to the primary backing, thereby reducing VOCs that are introduced into the building by the carpet. A variety of adhesives are included in the CRI Green label program. Water based adhesives are now available (see distributors below).

Rubber-based recycled padding is common and can outgas. Recycled padding from carpet fibers may be more suitable for environmentally sensitive persons. Carpet cushion is tested in the CRI program and a variety of cushion products qualify to carry the CRI Green label.

Recycling Old Carpet:

Purchasing new carpet means you have to get rid of the old and keep it out of the landfill (unless you choose a leasing or maintenance program to prolong the life). Ensuring that your old carpet is recycled and made into new products is very important. Although recycled PET carpet uses plastic that otherwise might be destined for the landfill, once the carpet serves its useful life, it is presently very difficult to recycle the carpet. Find a company that will keep your old carpet out of the landfill.

There are several major methods of recycling:

• Chemical: Chemical recycling involves breaking down the nylon itself to be reprocessed into new carpet fiber. Only certain kinds of virgin nylon compounds can be converted into new fibers. Check with manufacturers to see if your particular existing carpet brand and style is eligible.
• Waste to Energy: Products that cannot be converted into new carpet can be converted into fuel pellets for some applications.
• Fiberizing: Carpet fibers can be harvested and converted into padding and matting for use in laying new carpet.
• Mechanical: Carpet fibers can be separated from their backing material. If possible, the fibers are recycled into new carpet or backing. The leftover materials can be processed into products such as parking barriers, geotextiles, lumber alternatives, fiberboard, sod reinforcement, carpet tack strip or automobile parts, among other products.

Natural Floor Coverings (Other than Wood):

Natural linoleum is made from softwood powder, linseed oil, pine tree resins, cork, chalk, and jute backing. Recycled-content tile is available made from waste glass such as lightbulbs and auto windshields. Recycled-content tile is also made from a byproduct of feldspar mining. Linoleum and natural carpets use renewable resources and offer durability without compromising aesthetics. The cork used in linoleum is harvested from the cork tree on an ongoing basis without harming the tree. Natural carpets are made form grasses, cotton, and wool, with minimal treatment. Ceramic tile offers outstanding durability and maintainability, with a high aesthetic value.

Cost:

Recycled-content padding and carpeting are priced competitively. Recycled-content tile is higher priced than average tile products. The least toxic adhesives used with ceramic and recycled tile are locally available at competitive costs. Linoleum will cost more than low cost vinyl flooring. Natural carpet materials are more costly than common carpet materials, but competitively priced with standard high quality carpeting.

Purchasing Recycled-Content PET Carpet:

Polyester carpet fiber is produced from recycled PET (ie., soda and ketchup bottles). Some of the names which recycled fibers are marketed under include Resistron ISF, Resistron and Permalon. The carpet resists stains, fading and abrasion. PET fibers are naturally stain resistant and do not require the chemical treatments commonly used on nylon carpet. ScotchguardÓ coating increases the stain resistance properties. Fibers retain their color and resist fading due to sun or harsh cleaning. Shades can be richer and brighter than those found in nylon yarns. Because plastic beverage containers are made with top quality PET resins as required by the U.S. Food and Drug Administration, recycled PET is superior to lower grades of virgin synthetic fibers used in making other brands of polyester carpet yarns. PET has exceptional strength and durability and the value of these properties is not lost in their recycling process. Polyester has fewer emissions than nylon because it is made with fewer additives, and because it is inherently stain resistent. Easier maintenance reduces the use of cleaners which also emit VOCs.

At this time, there are no programs to recycle used PET carpet back into new carpet, but fibers can be recycled for other applications (car parts, insulation, transportation devices, stuffing for furniture).

Carpet Leasing and Reuse Programs:

Leasing is a new idea in floor covering whereby carpet manufacturers take complete responsibility for the carpet and maintain the carpet for the life of the facility for a monthly charge. Leased carpet will have the lowest first cost and the carpet is typically recycled at the end of its lease period. When the lessor wishes to remodel or remove the leased carpet, several options are available. Often the carpet can be removed, cleaned and reused within the same building, but the feasibility varies with several factors: age, wear and tear, deterioration of the materials, condition (rips and tears are generally difficult to remedy) and contamination: if the carpet has excessive animal fur and dander, or has been contaminated with animal wastes, it cannot be reused. Some carpet distributors will recover, clean and sell used carpet. Used carpet can also be mailed to the recycling center in some cases. A credit towards the lease or purchase of new carpet may be given.

Interface: Interface has a leasing program called "Evergreen" where for a monthly fee they will assume responsibility for care of the new carpet and take back the used carpet and recycle it into new products. You can also purchase the new carpet and they will still take back the old.

ReEntry is a system for reclamation of used carpet put in place by Bentley, Interface, Prince Street and Re:Source Americas, a national network of floor covering professionals. ReEntry promotes "repurposing: " clean and refurbished used carpet is offered to groups who could not otherwise afford new carpet. Any carpet purchased through Re:Source Americas from Bentley, Interface or Prince Street, and have existing carpet that needs to be disposed of, the ReEntry program will take it back an either "downcycle" it into other products or energy, recycle it, or repurpose it.

DuPont will facilitate leasing programs nation wide, providing installation, maintenance and recycling of nylon carpet at the end of its use. Other leasing programs are run by individual carpet distributors. Collins and Aikman lease carpet through DuPont.

DuPont (888) 844-6724

Shaw Industries also manages a leasing program; see below for contact information. With Shaw’s Tile Reuse Program, products which may no longer meet the demands of a corporate or hospitality setting are donated to organizations.

Milliken Carpet (carpet reuse): Earth Square or Earthwide Ennovations (E2) is Milliken’s name for it’s renewal process for used modular carpet. Milliken Carpet promotes the concept of reuse through a service installation and maintenance plan. It does not use recycled content in its carpet, rather stresses the importance of color, pattern, maintenance and cleaning to a carpets’ long life. They will take your old carpet tiles, then clean, rejuvenate, restyle, and reinstall with a new warranty for about half the cost of new installation. The modular system allows individual pieces to be able to replace worn or soiled tiles. After 8 to 10 years, the carpet is sent back for refurbishing and new carpet or carpet that has been refurbished elsewhere is installed. The E2 service is built on the fact that a sizable amount of commercial carpet isn’t replaced because it has worn out, but simply because it is "time for a change."

MilliCare Environmental Services program called Perpetual Floor Plan is a total package including maintenance and reuse options.

Currently, there are no known companies which run leasing programs for PET carpet.

What  Major Companies are Doing

BASF: BASF Corporation, a major supplier of nylon 6, through its 6ix Again program, takes used nylon carpet to one of four collection centers in the U.S. where it separates the face fiber and repolymerizes it to make new nylon. The 6ix Again program takes back other carpet besides BASF fibers.

BASF
(800) 477-8147
http://www.basf.com/commitment/ecology/econews/6ixAgain.html

DuPont Flooring: DuPont, another major supplier of nylon used in carpet (ie., Antron) operates the nation’s largest mechanical recycling system. Whenever DuPont Flooring systems removes and replaces commercial carpet, the old carpet, regardless of the manufacturer, fiber type or construction, is recycled. This reclamation program processes the used carpet into raw materials for a variety of uses such as automobile parts, sod reinforcements, soundproofing, and industrial flooring. MSA Industries provides local reclamation sites in major cities across the U.S., provided that the new carpet or carpet tile installed is made of DuPont nylon. DuPont is about to market a Type 6.6 face fiber containing post-consumer content reclaimed from used carpets. The new fiber retains the wear, stain resistance and dyeability features of Antron nylon fiber made from virgin material. DuPont’s process enables nylon to be recycled over and over again.

SelecTech is producing a new heavy-duty flooring product from used carpet recycled by the DuPont Carpet Reclamation Program. Called "RepTile," this is an industrial-strength floor tile, containing 50% post-consumer recycled carpet. It is available from the company, or locally from DuPont Flooring Systems.

Collins & Aikman: Collins and Aikman (C&A) use virgin nylon (DuPont Antron) in their carpet fiber because of its durability and appearance. They offer a pick up program where they will guarantee that old nylon carpet with vinyl backing is recycled into various products such as carstops, industrial flooring, and carpet backing. C&A Powerbond ER3 backing is manufactured with a 100% recycled-content backing and very dense, low pile nylon fiber to conserve materials use. Because the backing contains nylon from the face fiber of used carpet, it is more stable than traditional backing. C&A offer a tile installation system with no VOCs, eliminating the use of wet adhesives installation; no airing out is required. It is installed using "peel and stick" which is a dry glue-free adhesive (no off-gasing), available as modular tile and 6 foot rolls. The 100% recycled content backing results in an overall 28 to 52% total recycled content carpet. Powerbond ER3 backing is made from recovered post-consumer and post-industrial carpet, making it a closed-loop system. The carpet and backing can be recycled again after its 15-20 year life. C&A state that the backing has proven in tests to outperform its virgin counterparts.

This summer, C&A will introduce Antron Lumina, a closed loop 6.6 face fiber carpet made with post-consumer content with the ER3 backing.

Shaw Industries:
Shaw, a supplier of carpet yarn, carpet, and pad, collects used carpet and recycles it into a number of products, including carpet underlayment, new carpet, marine building materials, industrial felt, and plastic car parts. They have recently introduced a commercial post-consumer recycled content carpet called EcoSolution Q. When used with Shaw’s new 100% recyclable, reclaimed, non-PVC backing called Ecoworx, it makes a fully recyclable carpet tile. EcoSolution Q and EcoWorx backing approach a closed loop system. Old EcoSolution Q yarn will be used for injection-molded automotive parts; used Ecoworx will be melted down for new backing. The Type 6 EcoSolution Q yarn contains at least 25% post-consumer and post-industrial nylon waste. EcoSolution Q has the same easy maintenance and antimicrobial properties of virgin nylon, but requires much less water to produce. It comes in tile and broadloom. Peel and stick tiles use acrylic and cellulose and no VOCs.

Shaw makes Endurance TM II Carpet Pad, an underlay pad made from recycled carpet seams, waste yarn, and carpet selvedge (trimmings).

Shaw’s residential PET (polyester) carpet is not recommended for commercial use.

Shaw Industries
P.O. Drawer 2128
Dalton, GA 30722-2128
(800) 441-7429
http://www.shawinc.com

Interface:Interface has adopted a sustainable strategy to reduce, reuse, reclaim recycle, and redesign in all aspects of production. Interface will not landfill used carpet; some is refurbished and shipped to other countries. Nexstep backing is made from 100% recycled content and can be separated and reclaimed into new backing. Nexstep backing is used in the Wabi nylon carpet which has a low face weight. Interface’s DejaVu carpet line is made from 100% post-industrial and post-consumer nylon; total recycled content is 75% (fusion materials account for the non-recycled content). DejaVu is not recyclable into new carpet, but Interface believes that in 5-7 years it will be able to recycle the nylon face fiber into new face fiber rather than "downcycling" into auto parts and other products. It has a vinyl backing. Carpet comes in both modular tiles, no adhesives or VOCs, or broadloom, with the lowest acceptable level of VOCs. Interface is working on a 100% post-industrial nylon face carpet with a 70% post-consumer or post-industrial recycled-content backing that is 100% recyclable. Interface also makes a soft surface floor covering from recycled content called Solarium.

Interface Flooring Systems, Inc
P.O. Box 1503
LaGrange, GA 30241
(800) 336-0225
http://www.interfaceinc.com

PET Recycled-Content Carpet:

Image markets its recycled polyester carpet under trade names Enviro-Tech, Image, and Classique for both residential and commercial markets. Enviro-Tech system produces Resistron carpets with 100% reycled PET as carpet face fibers. Duratron carpets are made from combination of PET fibers and nylon.

Envirolon: Envirolon uses fiber made by Talisman Mills, Inc., consisting of 100% PET carpet advertised as commercial grade. Carpet is glued to the subfloor and adhesives meet air quality requirements. The backing is polypropheline. A web site is in progress.

Distributor information listed below.

For More Information On Carpet Options:

Greenbuilders Sourcebook (Austin, TX)
http://www.greenbuilder.com/sourcebook/floorcoverings.html

National Association of Home Builders Research Center
(301) 249-4000
http://www.nahbrc.org/homebase/fattest/wstcarpet.htm

The Carpet and Rug Institute
(800) 882-8846
http://www.carpet-rug.com

Manufacturers and Distributors of Recycled-content Cushion/Padding or Backing:

Three types of recycled and natural carpet cushion in the Nature’s Choice line. Cushions include: Pinnacle, made from 100% polyester derived from recycled plastic bottles; Dura, containing 92% recycled rubber tire tread; Ultimate, made from natural fiber coated in corn-based polymer. All cushions can be recycled again.

Carpet Cushion Associates
1248 Pametto St.
Los Angeles, CA 90013
(800) 244-6977
fax (213) 626-5959

A variety of carpet padding made from reclaimed and recycled fibers such as jute, hemp, acrylics, and cotton. Treated to be mold and mildew resistant. Surface coated for enhanced durability and ease of application.

Chris Craft Industrial Products
P.O. Box 70
Waterford, NY 12188
(518)237-5850

The Presidio Thoreau Center used C&A Powerbond ER3.