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December 8, 2022

How to Weave Oversized Rugs?

Throughout history, large carpet-weaving workshops were attached to palaces or government offices. States were constantly weaving carpets for new palaces, new mosques, gifts to other countries’ courts, etc. Among the known ones were Seljuk, Mamluk, Safavid, Mughal, and Ottoman workshops. These workshops did not have any cost concerns.

Another thing that makes them so special is their craftsmanship. Producing Oversized Rugs is the most delicate and hard work in the world. In our article, we will share hard-to-believe numbers and examples with you. Keeping this art alive is a priceless feeling.

Oversized rugs are classified as carpets longer than 6 meters (20 feet) in width or length. Producing these carpets is extremely difficult and requires special large looms and experience. The details in the designs are the sophistication of the traditional and modern symbols and colors in the patterns that adorn the designs. The perfect harmony of patterns and colors in carpets created with hundreds of thousands of knots is the result of passion and handwork. Our oversize carpets are woven in one piece on the world’s largest weaving looms, completely adhering to traditional methods, in natural ways. Today, as in the past, oversize rugs are produced as a result of special orders, which usually decorate the homes or places of wealthy individuals and families, or as a symbol of reputation in museums, palaces, churches, hotels, and similar areas. These are magnificent monumental rugs and a must-have for larger spaces.

Very special looms are needed to produce such oversized rugs. These are pieces specially designed, produced, and included in the inventory. Another important detail is that the area where weaving will be made is wide enough and that it receives light and air.

The durability of the weaving loom and its inability to stretch or deform during weaving directly affects the quality of the produced oversize rug. Ararat Rugs can produce oversize wigs of 100 square meters and over. This means that the carpet has a width length of at least 10 meters (33 feet). The weaving area and the studio have been specially designed to remove the carpet, which has been produced on the loom and moved for other operations. Imagine that an oversized carpet is made and trapped within the weaving area. For this reason, you need to consider all the engineering details for the production of oversize rugs.

Before you start weaving a carpet, you need to warp the loom by the order and design. This very important process is vital for oversized carpets. These procedures are only done by those with expertise and can sometimes take weeks.
Warping a loom directly affects the quality and durability of the carpet. It is essential that the threads are sufficiently stretched, that they do not deteriorate during weaving, and that the processes are carried out using the right material. These processes are done by the people who prepare the loom.
We would like to give you a simple example; to start the production of a 45-square-meter carpet, you need to prepare the loom and complete the warping loom processes. Unbelievable, but for this warping a looming process, you need to use about 55 kilometers of rope and complete them in a certain order without any errors.

The weaving process of a 50 square meter carpet takes approximately 250-300 days depending on the weather or the weaver’s conditions. As explained here, your loom and weaving area is the first part of the job.
Another important step in the finishing process is the washing process. Why is it so important? Think about it, a 50 square meter carpet weighs about 100-120 kg. It is a fact that you need a very special area for cleaning operations. When washing this rug, the weight will increase 8 to 10 times. The new weight of the carpet waiting to dry will be more than 1000 kilograms (more than 1 ton). It will also need a space to dry the carpet with natural methods. We need to have the right plan, team, and equipment to carry out customers’ order for such an oversized carpet and deliver it to our customers as promised.

As with all carpets, finishing processes are applied for oversized rugs as well. For Oversized Rugs, these processes are possible with a very special team, equipment and experience. For dusting processes, we use wooden drum mechanisms made of natural materials that we have developed entirely ourselves. In these operations, it also adjusts the brightness of the natural material (wool) ideally.
Natural wool is a non-combustible material. We obtain the colors from nature without using any chemical materials and burn them to give the carpet its final shape within the finishing processes of a carpet. The incense and burning processes as the first step to removing the fuzz on the backside of the carpet. But you need a huge and well-controlled area to do these operations with a flamethrower. For oversized rugs, these processes are carried out by experts who are experienced in the burning process.
Oversized Rugs are made by passionate professionals. Your order of oversized rugs is produced in approximately one year, depending on the size, completely using traditional methods, including antique or modern designs. You can access our ERP system online and track & monitor the status of your carpet simultaneously. We have to think about everything and this job is no mistake.
The steps involved in finishing processes such as washing, stretching, and weeding are also made by human hands, special skills, using natural methods as promised in very special courses.