No, this isn’t about rows of corn planted on a highway; it’s about those furrows that develop in a carpet that look just like rows of corn. In this case, the corn rows run across the width of a hallway in a residence. The carpet has been down for about 2 years. The condition was noticed about 1 year after the installation. The product is a thick, tall, heavy; 80 ounce nylon cut pile with a fairly loosely plied yarn. The carpet is installed stretched in over a heavy slab rubber pad. The consumer complained to the dealer about the condition and the dealer filed a claim with the manufacturer.
When the carpet was inspected the report stated that the cushion was too thick and that the corn row condition was not a manufacturing defect. The dealer did not agree because the inspector had several facts wrong, including the type of cushion used. Another inspection took place, this time by a different inspector. Basically, he said the same thing but he also stated the vacuum cleaner had a part in the condition. The vacuum cleaner being used is an upright machine with a beater bar and brush.
This dealer has sold thousands of yards of this product over a period of over six years without a claim. It has been installed in dozens of homes just like the one in this complaint and nary a peep was heard from anyone who bought the carpet. Because of this he felt there was a defect in the carpet but, after the second inspection, the claim was again denied.
There are manufacturing conditions that could cause corn rows in a cut pile carpet, namely gauge lines and “J” cuts but these will always run the length of the carpet and would likely be noticeable right away. The corn rows in this carpet run across the width in traffic lanes. Actually, the one inspector hit on an issue that was a contributor to the problem. First though, because this carpet is so thick and fairly loosely plied it is prone to matting and crushing. An aggressive vacuum cleaner with a beater bar set too low can create corn rows. The vacuum will grab the yarn, pull it along the roller, discharge it and repeat the process. This grab and release action repeated can cause the corn rows in the carpet. The corn rows could possibly be eliminated by grooming the carpet with a Handi Groom or a Dandi Groom. This is a comb like device, similar to a push broom or nap brush, that will lift and separate the nap of the carpet and has the capability, used regularly to level out the carpet and thus eliminate the corn rows. The downside is that the condition, once set, can come back and every time the carpet is vacuumed the corn rows will return. Unfortunately this condition is not all that uncommon.
The consumer is ready to sue and the dealer is frustrated. The carpet does have a two year appearance retention warranty that, depending on how it reads or is interpreted, could bind the manufacturer to honoring the claim. The appearance warranty was never mentioned by the dealer to the manufacturer because he was concentrating on the corn rows. The warranty issue didn’t come up until he and I discussed the situation. If the warranty covers or suggests that the appearance of the carpet should not change for a period of two years then it may be cause enough to replace the carpet. If the case goes to small claims court a judge, given the right information, presented properly, and given the history of a product that has never done this before could very well sympathize with the consumer and the dealer. If you need help call us. You may have options you overlooked.
Author: Lewis G. Migliore
LGM and Associates – The Floorcovering Experts