Newsroom > Repairs: Plug, Patch or Precision Bonded Insert?

If your repairs are done with skill and care, and leave the repaired area looking as good as the limitations of the carpet will allow, terms such as "precision bonded insert" or "surgical pile grafting" may be more appropriate than "patch" or "plug".

To perform a patch, all you really need is a scrap of carpet slightly larger than the damaged area, a hammer and some nails.  For a plug, a cookie cutter will do just fine.  For a precision bonded insert, you will need several specialized tools:

1. Double-edge slotted razor knife.
2. Seam sealing adhesive.  (Solvent-based designed for sealing seams on direct glue installations.  
3. Large verterinarian syringe such as the kind used to inject deodorant into carpet backings.
4. Professional hot melt glue gun. (optional)
5. Needle nose pliers.
6. Napping shears.

A suitable Donor

To begin, the area of carpet damage must be a good candidate for transplant surgery.  This means that the area to be repaired should not be larger than say the size of a household iron.  The area must have sufficient structural integrity as well, since this procedure requires  that new carpet pile and primary backing be surgically bonded to the existing secondary backing.  The trauma must have occurred only to the surface of the carpet.

If the trauma has extended to the secondary backing as in the case of over application of cleaning solvents or burns that penetrate through both backings, a surgically sectioned implant would be the recommended procedure.

Finally there must be a suitable donor.  The donor material may be obtained from a piece of carpet left from the original installation, from a closet, from  under a stationary piece of furniture, or even from the edge of the carpet if the carpet can be stretched and the damaged area is small.

Be sure to mark the back of your donor piece with an arrow to indicate the pile direction, this is necessary for correct orientation when inserting into the host.

You can be creative in the selection of a donor and, while an exact match will give you the greatest chance for succeeding without rejection, you should inform the customer that an exact match between donor and host is rare and there is likely to be some visual difference in the area of surgery.  This being said because the nature of this procedure, success is often achieved with this disclaimer "you can expect to see the repair because you are aware of the exact location. A guest in the building should not, nor shoul dyour eye be drawn to the repair when entering the room."

Step by Step

1.  Remove the damaged face yards and primary backing from the area to be repaired.  This must be done without damaging the secondary backing leaving it intact for proper bonding with the primary backing on the donor.  This can be accomplish by removing all carpet tufts one by one with needle nose pliers, pulling them out on cut pile by securing one side of each tuft and applying upward force sufficient to remove each tuft. 
   On looped pile carpet you will need to sever the end of each row cleanly prior to row removal.  Alternatively, you may elect to remove the carpet tufts around the perimeter of the damage, then using the needle nose pliers and your razor knife, carefully cut only the primary backing and peel it and the remaining tuft from the secondary backing.  Practice and experience will dictate which method you choose on any given repair.  After complete removal of the primary backing be sure to square all edges.  Clean edges make a clean repair.
2. Remove the secondary backing carefully from the donor.  This needs to be accomplished before cutting the donor to size as the process will leave the edges damaged.  Be sure to mark the backing of the host with an arrow to indicate the pile direction since you have removed your previous arrow.
3. Carefully cut the donor to fit the exact dimensions of the now bare secondary backing on the host carpet.  The donor must not be larger than the host area or you will end up with a patch.  It is better to be slightly smaller than larger, although with care you will be able to create an exact fit.
4. Apply adhesive to the exposed secondary backing of the host carpet.  Remember to insure a proper fit prior to applying the adhesive.  You may use hot melt adhesive or the Dap seam sealer.  The choice of adhesive will be based on the size of repair, personal preference and experience.  Seam sealer works well.  It dries flexible and is relatively easy to work with.  When you do chose the glue gun you must be careful not to over apply the glue, you must also be ready to fit the donor piece exactly on the first attempt.  The solvent-based seam sealer when used will be applied with the  use of the large syringe.  Several minutes open time will allow you the time you need to fit the donor piece correctly.
5. Press the donor firmly into the host.  Using the seam roller, track and groom and apply weight for 20 minutes using a seam weight..  After 20 minutes, remove the seam weight and allow 2 hours for a permanent bond.  The time required for a permanent bond will vary depending on the size of the repair, amount of adhesive and type of adhesive  used.
6. Trim the edges.  After careful inspection trim the edges with napping shears.
7. Call the customer for inspection, after insuring that you have exceeded their expectations.

The is a general description of the repair process for minor damage to the surface of the carpet.  As always, spend time practicing your repair techniques before performing them on the customer's carpet.

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