It seems easy enough — rugs are either made by hand or by machines; however, it is really not that simple at all. The truth is that there is no way around it; area rug construction is an involved topic. It is not terribly complex but there are many issues to cover.  Moreover, it is a subject of importance and worth learning as it will help ensure you purchase the rug you really want. It is also the one rug topic that deals with abstract concepts that are too often overlooked and creates a bright line that divides buyers.

This article will provide an introduction to area rug construction. Part I will identify the issues and explain why construction is important. Part II will discuss hand made rugs and give a brief description of each technique used to craft rugs by hand. Part III will cover machine made rugs and highlight there advantages.


How an area rug is made is one of the most important subjects in buying and understanding rugs. Like fiber, rug construction is often an after thought for many shoppers; however, it will dictate quality, durability, price, and value. Moreover, it speaks to the less tangible but ever significant issue of craftsmanship. It is the human touch that elevates a rug from a floor covering to a work of art. It is the skill of the weaver that can make a rug a masterpiece. As fiber is the foundation of a rug that determines its body, construction is the heart of a rug that establishes its soul. And this is exactly why construction is so important yet so difficult to explain, these concepts get lost on many buyers who are “just looking for a rug” and highlights the divide among buyers. Simply put, certain hand made area rugs are like original oil paintings, while machine made rugs are like replicas of the original. Both are beautiful. Both will decorate your home, show your style, and start conversations. However, they are very different in terms of how they were produced and how they are valued and priced.



As a general rule, handmade area rugs are usually more expensive than a power loomed rugs, but like most rules there are exceptions. One being that surprises some people is that there are less expensive handmade area rugs woven with synthetic fibers.  Thus, it is important to remember that regardless of the quality of the construction method, skill of the weaver, or the efficiency of the loom the ultimate quality of a rug will also be dependent on the fibers it is woven with.

Handmade rugs can be hand-knotted, hand-tufted, hand-hooked, hand-woven, hand-loomed, hand-crafted, and braided.  This article will focus on hand-knotted, hand-tufted, hand-hooked, and hand-carved area rugs since they are the most popular. With handmade area rugs their quality is always dependent upon the skills of the craftsman and the fiber they use to weave it.

Hand-Knotted Area Rugs

Standing alone atop the area rug hierarchy are the hand-knotted. It is the oldest and most impressive method of construction. No other technique can compare. These rugs are meticulously constructed by tribes of skilled weavers that have been creating rugs for thousands of years. The craft has been passed down generation to generation and continues today. Making rugs is a way of life for these people. It is their job, their social experience, their avenue for expression.

Superior Craftsmanship

Each rug is made by hand tying thousands of individual knots. Fine hand knotted rugs will have hundreds of knots per square inch. Each knot has a purpose and a plan. Out of this process the weaver(s) create the rugs intricate designs. A single hand-knotted area rug can take months, and often years, to complete. Accordingly, they are also the highest priced area rugs.

Perfectly Flawed & Unique

No two hand-knotted area rugs are alike. Each is unique and special and worthy of the price it demands. This point also illustrates why machine-made area rugs and to a lesser degree hand-tufted and other hand-crafted rugs are considered inferior - they produce identical copies of a rug. As far as originality and being a true one of a kind, nothing comes close to an authentic knotted masterpiece. Experts also argue that machine-made replicas lack the intrigue and beauty of craftsmanship and other hand-made area rugs will never increase in value. Further, they note that the precision of machine made rugs remove the true beauty and what is wonderful about hand-knotted area rugs — Their flaws.
 
The flaws in a hand knotted area rug reflect the humanity of the weaver. The ancient Persian saying highlights this point: "A Persian rug is perfectly imperfect, and precisely imprecise." Not only does that saying point to the pride and tradition in Persian hand-knotted area rugs but also reflects the beautiful Muslim belief that only God can be perfect. The fact that Persian’s have been meticulously weaving rugs for thousand of years, make the world’s finest rugs, and even they are flawed proves their sacred belief.

Complex Pre-Weaving Process

While explaining types of knots and how they are tied is beyond the scope of this article it is important to note that constructing the rug is just one step of making a traditional Persian hand-knotted rug. Before the first knot is tied the weaver hand spins wool they sheer from their flock and process the yarn. The yarn is then hand dyed and made ready for weaving. Learn more about how hand-knotted area rugs are made.

Amazing Value

 
Remember value is not about the price of an item; it is about what you get for the price you paid. Most people consider hand knotted rugs to be an excessively expensive luxury. Considering the meticulous weaving process and the quality of the final product one can compelling argue that the opposite is true and that they are a terrific value. In fact, the usually true phrase, “You Get What You Pay For” is very wrong here. Buying a hand-knotted area rug is like paying for the raw materials and getting the yarn, dye, labor, expertise, artistic expression, and beauty for free.

Further, these area rugs are woven with the finest wool and are heirlooms that will last for generations if properly cared for. In short, if price is not an issue and you have a room that gets light traffic buy a hand-knotted area rug – it is a fine work of art.

Hand-Tufted Area Rugs

Most of today’s handmade carpets and area rugs are tufted. Hand-tufted area rugs are made by using a tool called a tufting gun, which saves time and money. This method is most common in China and India, but is used throughout the world. A room size hand tufted rug can usually be finished in a few days. These rugs are so popular because they offer a hand crafted rug at a lower price point.

Intermediate Craftsmanship

While these area rugs are considered handmade they depend heavily on the use of tools and should not be confused or compared to a hand-knotted area rug. In brief, hand knotteds are better made and more likely to stand the test of time. The level of skill and craftsmanship is also much different between the methods. Case in point, hand-knotted area rugs takes a team of skilled weavers months and even years to complete. As noted, an 8 x 11 hand-tufted area rug can usually be completed in a few days.

How They’re Made

These rugs are constructed when the craftsmen uses the tufting gun to force piles of yarn through the primary backing material known as a scrim. The scrim is basically a canvas, which is stretched on a frame. The design of the rug is sketched on the canvas to guide the worker and direct them on the color of yarn to use. This process forms a looped pile, and if left uncut the rug is often referred to as hand-hooked. If the loops are sheered off to create a cut-pile look, it is referred to as hand-tufted.
 
Since knots are not used to make these rugs glue is used on the back of the scrim and the back of the rug to hold it together. Although it is rare, the glue can weaken over time causing the pile to separate.

Perfect Hand-Made Option 

 
Hand-tufted rugs offer a middle ground for buyers who want a hand-made area rug. They are less expensive than hand-knotted area rugs; but, more costly than machine-made rugs. They possess the personalization and a level of craftsmanship not found computer programmed machine made area rugs. If a level of craftsmanship is important to the buyer but the price of hand-knotted rugs are prohibitive than hand tufted area rugs are the perfect option.

Hand-Hooked Area Rugs

Hand hooked area rugs are as American as apple pie. In fact, rugs have been hooked in America per-dating the Declaration of Independence. Since colonial times women crafted area rugs using scrap materials to add warmth to floors and beds.

Today, hooking rugs the tradition of hooking rugs is alive and well in America. These rugs typically portray country themes. They are mass-manufactured and produced by hobbyists who enjoy the popular craft. Modern hand hooked area rugs are made from cotton, wool, and even synthetic fibers.


When a hand crafted area rug is completed is usually cut of sheared to even the pile. Once that process is finished the rug may be hand-carved to add elements of style and texture to it. Hand carved area rugs require specialized tools to accentuate details of the rug. Even some tufted and machine made rugs are then hand-carved. Hand carved area rugs can be more valuable than level or even pile rugs. Regardless, hand-carved rugs possess added style and interest. 

Since the mid 1800s powered looms have been used to weave machine made rugs more efficiently. This process reduces the time to construct an area rug and saves money. These area rugs are often called Wilton Woven, engineered, power loomed, or machine made. Historically, these rugs were made in Europe. Currently, Belgium, China, Egypt, and the United States are major producers of machine made rugs. Beyond price, a contributing factor to their popularity is the selection of fiber used to weave them. They are made using the finest wool and natural yarns. Synthetic fibers are also used to further reduce the price point.
 
Computers are now used to perfect the design and program rug looms. This development makes any imaginable design possible and efficient to create. Manufactures have also perfected novel means to weave machine made area rugs. For example, they are now side-woven or cross-woven, which allows for a wider range of colors to be used. For example, Sphinx by Oriental Weavers boasts including 92 colors in a singe cross-woven area rug. The technique also enables fringe to be incorporated in the rug versus sewing it on post production. This also illuminates an important point, not all machine made area rugs are of equal quality. There is as much variation among power-loomed rugs as there is with hand-mades.
 
Additionally, machine made area rugs are woven very tightly and usually have a thicker and tighter pile than most handmade rugs. It is common for them to have 1 million points per square inch. As a result, they are very durable and can withstand high traffic areas.  A well constructed machine made area rug can easily last 20 years of heavy traffic use. Considering how well they are made, their durability, and lower price it is easy to understand the value of machine made rugs and their tremendous popularity.

In fact, machine made area rugs are extremely popular and account for the majority of rugs sold. The primary and obvious reason for this is because they are far less expensive than their handmade counterparts. The price advantage they offer is obvious when they are made from natural fibers. If fiber is important but you aren’t concerned with how it was woven than you can save hundreds and even thousands by purchasing a machine-made area rug. Machine made polypropylene or other synthetic area rugs provide even lower price points. In fact, there is a quality machine-made area rug available to fit any reasonable budget. Of course, they are also easier and more efficient to produce. While a hand-knotted rug can take months and even years to complete, a machine-made can be completed in a matter of minute. 

Area rug connoisseurs are quick to note that machine-made rugs are imitations of traditional hand-knotted rugs. They feel that machine-made area rugs lack the authenticity and wonder of handmade rugs since they produce identical copies of rugs and because they are not knotted. Most rug buyers aren’t moved by the argument and just don’t care. Money talks and machine-made area rugs speak their language. Indeed, machine made rugs offer great value and fulfill the need for an area rug. They are beautiful and will transform and immediately upgrade the look and mood of any room. Very few, if any people, will know or care how your rug is made. Instead, they will focus on its obvious beauty and how it transformed the look and atmosphere of your room.

The value of well constructed machine-made area rugs is undeniable. They are available in a wide range of fibers from the finest wools to more economical and family friendly (stain resistant) synthetic yarns. The synthetics offer tremendous savings and make owning an area rug practical for many people who otherwise could not justify the expense or risk of owning an hand-made. A very important factor in deciding on construction is your life-style and where the rug will be placed. Machine made area rugs are perfect for active "lived in" homes. They are very durable and their lower priced suits a more relaxed atmosphere.  This is particular true with synthetic machine made area rugs, since they are stain resistant and easy to clean. If you are looking for the lowest price and are not interested with a rug’s pedigree or if you have a very active home a machine-made are rug is the right choice. It will save you money, satisfy your needs, and exceed your expectations.