Continuing the quest of Roger De Clerck, founder of Beaulieu Belgium, Mieke and Carl Bouckaert established Beaulieu of America in 1978 as the first producer of polypropylene oriental rugs. As sales grew Carl and Mieke invested in yarn extrusion in 1981 becoming the first manufacturer in the carpet and rug industry to produce their own yarn. Sparked by continued growth, the Bouckaerts diversified into tufting carpet in 1984, establishing a factory known today as Beaulieu Commercial in Chatsworth, Georgia.
In 1987, Beaulieu of America's extrusion capacity was greatly increased with the addition of the Bridgeport, Alabama facility. This modern facility gives Beaulieu the ability to produce nylon polymers and nylon yarns. In 1990, Beaulieu continued its vertical integration with the addition of yet another new facility in Bridgeport, Alabama for the extrusion of polypropylene staple fiber, polypropylene slit film, and weaving of primary and secondary backing.
The expansion in yarn extrusion and polymer capacity is being driven by the growth of the carpet and rug manufacturing. From the first carpet manufactured in 1984 to the acquisition of Conquest Carpet Mills, Interloom, Coronet Industries, Grass More and D&,W Carpets, through the establishment of Murray Fabrics, Beaulieu of America has rapidly grown into the world's third largest carpet producer. With the additions of Marglen Industries, Columbus Carpet Mills, and Peerless Carpet Corporation, Beaulieu of America has further strengthened its position as the number three soft floor covering producer in the world.
Beaulieu of America also looks outside the U.S. borders for growth opportunities. In 1980, Beaulieu Canada was founded for the manufacturing of woven rugs. The 1990 purchase of Coronet yielded Coronet Canada, the second largest manufacturer in Canada. In 1998, Beaulieu acquired Peerless Carpet Corporation, then the number one carpet producer in Canada. This acquisition secured Beaulieu Canada's position as the largest manufacturer of Carpet in Canada. Overseas production was expanded in 1995 when Beaulieu acquired an Australian Manufacturer, Sterling Carpet Mills, creating Beaulieu Australia. Beaulieu Australia features state-of-the-art extrusion for the production of BCF polypropylene and nylon fibers following the vertical integration philosophy of its parent, Beaulieu of America.
In 2002, Beaulieu of America decided to concentrate strictly on broadloom carpet, and sold its rugs and hard surfaces divisions. This has allowed Beaulieu to focus its efforts on manufacturing high-quality, affordable broadloom carpet.
From several superposed layers of fibers, the needling technique consists in hanging the fibers together through the use of special needles. The carpets obtained are very solid but intended for temporary use since they do not provide comfort.
Stylish enough to be the focal point of any room yet resilient enough to stand up to the elements, our Indoor Outdoor carpet styles are perfect for sunrooms, patios and more.
When softness and comfort are top on your list, plush carpet offers a more luxurious feel than other cut pile carpet. A plush carpet has a dense, deep pile. However, are subject to vacuum cleaner sweeper marks and footprints due to light reflection.
Berber Carpet is Loop-pile carpet tufted with thick yarn, such as wool, nylon or olefin. Often having random specks of color in contrast to a base hue, this floor covering has a full, comfortable feel, while maintaining an informal, casual look.
The tufted carpet is the most common manufacturing technique. It implies poking yarn tufts in a textile support close to a sewing machine. The carpet is then equipped with a folder (rewoven, jute, plastic or cotton) pasted on the back of the tuft.
A sculptured cut and loop carpet has a combination of high cut tufts and lower loops create a variety of sculpted patterns. Patterned carpet also adds a dimension of texture within a room and hides traffic patterns.
The woven carpet is one of the oldest manufacturing processes. It is woven like a carpet through a traditional weaving loom. The top and the back of the carpet are made simultaneously.
Juvenile and kid rugs, also called kid rugs are really activity and learning centers on the floor, where your child can spend time being occupied with age appropriate games and adventures. They can provide a warm, comfortable setting for kids.
Textured cut piles, trackless or foot-print free show fewer footprints and sweeper marks than other cut pile carpets. These constructions curl the fiber to reduce light reflectance and the appearance of footprints.
Luxury Vinyl Tile comes in a variety of lengths and widths. Therefore, it’s better suited for imitating materials like stone, granite, and concrete. LVT can float, peel-and-stick, be glued down, or snap together for easy installation.
Luxury Vinyl Plank can mimic the look of traditional hardwood floors. They can float, be glued down, or snap together. LVP can also be smooth or textured to mimic different types of materials.
Waterproof flooring offers superior performance in wet areas, such as basements and bathrooms and provides easy maintenance for spills. Plus it is easy to clean because it keeps spills on the surface making cleanup tremendously easy.
Engineered hardwood has a thin solid wood layer on top with a composite core. It can be a less expensive option than buying hardwood, but it cannot be sanded and refinished. This flooring typically is installed with a click-lock method.
Many different species of wood are fabricated into wood flooring in two primary forms: plank and parquet. Hardwoods are typically much more durable than softwoods. Wood is a common choice as a flooring material and can come in various styles, colors, cuts