Historic Reproductions
Over the past 30 years’ The Rug & Carpet Studio has built a reputation for their knowledge and expertise in traditional and historic carpet designs. We replicate carpet designs from all over the world – from traditional hand knotted Persian designs that date back hundreds of years, through to Axminster or Wilton carpets that were first hand woven from 1755 and later machine made with the invention of the looms in the early 1800’s. We are often approached to copy old carpets that have seen better days or where the original has vanished or been destroyed. We have the ability and expertise to to reproduce the most complex of designs.
In many historic properties carpets were originally designed and woven to match the décor in the rooms. These carpets are just as historically important today as the rest of the décor and furniture and our ability to recreate them allows historic properties to protect their original carpets as they start to show wear and tear. The reproductions give properties options to protect their existing carpets, by leaving the original in situ and laying the new carpet over the top Alternatively, the original could be rolled up and safely stored, to allow the replica to be installed in its place. This allows households to receive extra visitors, on top of a more useable and manageable carpet, whilst still keeping the same decor in the furnished room.
This process has been successfully completed in historic properties throughout the UK, and is giving house managers and curators the confidence that their irreplaceable items are protected, but also still on show.
Hand knotted reproductions
For the past 10 years we have successfully worked with the weavers in Nepal to produce traditional Persian design carpets. We use software developed in Nepal to generate the designs and we colour match wool tufts to the original carpet colours. Samples are made, which allow for any tweaks to be made in either the colours or designs.
Machine made reproductions
As well as hand knotted reproductions, we are also able to produce British machine made carpets of Axminster or Wilton quality. We have the options of various different qualities and widths and they can be made with up to twelve different colours by using different looms. These carpets can be laid over the existing carpets if necessary, to help preserve the original carpets. Alternatively, these can be made to just cover the areas of the original carpets that the public walk on. The designs can be matched flawlessly enabling then to sit on top of the original without detracting from the historic feel of the room.
Please contact Pat Clark, our Design Consultant, with all enquiries. Included in our quotes are site visits, all design work, colour matching and samples, underlay (various options are available), delivery, and installation of the final carpet.
Case Study – Standen House Runners
The grand staircase located in Althorp’s saloon, built in the 1660s, has outlived many carpets over the years. In 2017, The Rug & Carpet Studio created a hand-made carpet in Nepal that was specifically engineered to endure for over a century.
In a video below, Lady Spencer and Sara Tatum discuss the history and creation of this beautiful carpet. The case study delves into the processes involved, from the designing to the making of the carpet.
The condition of the runners has deteriorated over years of constant use, and they are particularly fragile where they have been cut down and joined back together. Therefore, the decision was made to lift the old Ushak runners and retire them to archive storage.
With the advent of modern technology, it is now possible to recreate an original design. By working with similar textured wool and carefully matched colours, we can replicate original carpets and rugs in a strong and durable quality. The design is computer generated from detailed photographs and drawings of the existing rug. Extensive research and cross referencing allow us to incorporate the subtle design changes and character of the original piece. Detailed colour referencing is conducted using our extensive wool tuft box.
Once the design artwork and colours have been finalised by the client a sample is woven. In this instance two samples were produced in the ’60 knot’ quality, which closely matched the knot count of the existing runners. One sample was made using New Zealand Wool and the other using Tibetan wool.
Tibetan sheep have a harder life living at a much higher altitude. The wool they produce is thick and wiry in texture with a higher lanolin content (the natural oil in the fleece). The spun wool has a much more uneven texture and a higher lanolin content, which when dyed produces a softer, mottled appearance. It was decided that the Tibetan wool with it varying tones in the sample best represented the original quality and abrashed (meaning colour change) finish of the existing runners.
Careful measuring of dye powder is conducted by the expert dyer on extremely sensitive scales to carefully match the colours to the sample. The dye powder is added to the dye bath of hot water and then the wool is plunged into the bath and left to absorb the colour. The dyes are chemically based aniline dyes, which have been developed to look like old natural dyes.
The weaving takes place in what appears from the outside to be a rather smart private house in the quiet suburbs of Kathmandu. The ground floor of the building is used as workshop space and several looms are set up by large open windows with views of the garden and mountains beyond.
The cotton warp threads are evenly tied to the framework of the looms. The tension of these warps needs to be even and regular to produce a flat and strong finish to the rugs or runners. Printed artwork of the design is given to the weaver and from this artwork individual knots of wool are tied to the warp threads replicating the design. During the knotting process, the wool is wrapped around and through two warps and over a metal rod which helps to control the tension and pile height. The design is built up horizontal row by horizontal row. At the end of each row the rod is cut off the loom and the pile tuft revealed. In between each row a cotton weft thread is woven between alternate warp threads. This is then taped in place with a large heavy comb to hold the knots in place and give the rug strength and tension.
Once the rugs and runners have been made, they are removed from the looms for finishing and washing.
During this process, the sides are bound, and the rugs are washed to remove any loose dye. The wool is brushed to bring the shine and lustre to the surface.
From the initial enquiry to the final artwork, the process took seven months and involved many hours of detailed design comparisons and subtle artwork alterations. The weaving process took an additional five months, so overall the project took a year to complete.
Case Study – Althorp – The Spencer Staircase Carpet
The grand staircase located in Althorp’s saloon, built in the 1660s, has outlived many carpets over the years. In 2017, The Rug & Carpet Studio created a hand-made carpet in Nepal that was specifically engineered to endure for over a century.
In a video below, Lady Spencer and Sara Tatum discuss the history and creation of this beautiful carpet. The case study delves into the processes involved, from the designing to the making of the carpet.
During site visits, we spent time finalising the colours and finish for the new carpet. Small samples were woven with various finishes, and we ultimately decided on a light antique finish. We then had a large sample woven to drape on the staircase, giving us a good impression of the final product.
We also discussed at length how to ensure the maximum longevity of the new carpet. After careful consideration, we decided to weave the carpet (20.27m x 2.73m) in two separate pieces, each slightly longer than needed. This extra length allows for small amounts of the carpet to be tucked under and revealed in future years. The plan is to lift, clean, and re-lay the carpet every 10-15 years to extend its lifespan. The carpet’s edges are the most prone to wear, so the extra size allows for it to be moved a few inches at a time, either up or down. This approach will ensure that the new carpet lasts for generations of the Spencer family to come.
To generate the designs, we used software developed in Nepal and wove samples of the carpet, which allowed us to make any necessary tweaks to the colours or design. After Lord and Lady Spencer approved both the artwork and samples in January 2017, we commissioned the new carpet to be woven.
Computer generated artwork of the top section of the carpet
The computer-designed artwork and the necessary wool and dye formulae were sent to our colleagues in Kathmandu, where the carpet was to be made. The design program’s built-in formulae helped determine the exact amount of wool and dye required.
The master dyer carefully measured the dye powder on precise scales to ensure it matched the sample. The powder was then added to a hot water dye bath, and the wool was submerged to absorb the colour. To achieve the desired consistency, we used chemically-based aniline dyes, which have been developed to mimic natural dyes. Chemical or synthetic dyes were introduced into handmade rug making about 100 years ago.
Design your own rug
The Rug & Carpet Studio’s innovative bespoke rug service attracts commissions from interior designers and private clients. Our skilled weavers in Nepal and India practise the ancient art of weaving to produce exquisite hand-woven silk and wool rugs exclusively for us. We offer all customers a highly professional design service. This service includes an initial consultation either in our design studio or an on- site visit. Whether you want to match a colour scheme, fill a particular space, incorporate pieces of furniture or complement artworks, our bespoke service allows you to adapt an existing design from our extensive catalogue in your choice of colours and sizes, or we can work with you to create something entirely new.
Our experienced in-house designers are on hand to guide, discuss, draw up design ideas and give expert advice on techniques that might be most suitable. Using our specialised software our designers can produce an initial graphic image of how your rug will look.
This unique tiled rug specially designed on request by our client
Size, Shape & Colours
Our rugs can be made in all sizes – we design to suit larger scale spaces through to smaller rooms in the home. Most of our clients choose a rectangular or square rug but we can create rugs in any shape and size, from circular rugs to long thin runners. We will always offer advice on the most suitable weave for your design
With 100’s of colour tufts to choose from there is no need to compromise and we also offer a ‘dye to match’ service. We have a selection of yarns and many different weaving techniques which can all be incorporated to produce the perfect rug.
Weaving your rug
Once you are satisfied with the finished design and colours, the wool is dyed and the rug is hand-woven by our team of master craftsmen. Delivery time is usually 12 to 14 weeks but this is dependant on the size of the rug and may take longer. If it is a particularly large rug then a small sample can be produced for approval. It is at this stage that any design or colour corrections can be made. We simply ask for a 50% deposit paid upon approval with the balance payable upon delivery.
The Master Dyer & Dye Workhop
The carpet was made from wool sourced from New Zealand sheep. This type of wool has a fine, consistent texture that readily absorbs dyes, resulting in a uniform colour tone throughout the carpet.
During the weaving process, the cotton warp threads were evenly tied to the framework of the tall vertical loom. The tension of these warps needed to be even and regular to produce a flat and strong finish to the carpets. To create the design, printed artwork was given to the weavers who tied individual knots of wool to match the colour and layout of the design onto the warp threads. To maintain tension and pile height, the wool was wrapped around a metal rod during the knotting process. Once a horizontal row was completed, the rod was removed from the loom to reveal the pile tuft.
After the carpet was woven, it was finished and washed. The sides were bound and the carpet was washed with water to remove any excess dye. The wool was then brushed to bring the shine and lustre to the surface.
The 10-month production process culminated in the arrival of the finished carpet in the UK. We hired a specialist firm to have the carpet installed on the staircase in December 2017.
Case Study – Bespoke Juliette Carpet – Size: 7.20m x 6.35m
The Society of Apothecaries, a livery company with its historic hall in the City of London, contacted us because their original Axminster carpet situated in the Court Room needed replacing; the passing of time and heavy traffic generated through the commercial use of the room had led to the carpet becoming damaged and worn in places.
To replace the Axminster with a traditional hand-knotted carpet at a size to fit the room (9.14m x 9.14m) was not a viable option as antique carpets are rarely found in this size and the cost to produce a new hand-knotted carpet such as this was prohibitive for a carpet which would still have to withstand heavy wear and tear.
The Juliette carpet is hand-tufted with a 100% New Zealand wool pile, renowned for its quality in terms of softness, durability and colour clarity, which makes the finished product comparable to a hand-knotted carpet. The border design of the Juliette carpet was inspired from a border of a traditional carpet and the all-over pattern was created in a similar style. The design works with the room and allows for the varying placement of furniture.
A sample of the design was made and viewed in the room as the as the colours can look very different in situ.
With the Court Room’s dark oak panelling, the deep red colours of the first sample appeared too dark and a further sample was produced in brighter tones. This looked perfect and was made into the beautiful Juliette carpet found in the Court room today.
Our knowledge of historic carpets and settings, combined with our expertise in production, has enabled us to design a carpet sympathetic to the room. The carpet is durable enough to withstand wear and tear and has been produced at a fraction of the cost of replacing the Axminster with an antique carpet.
Case Study – Bespoke Horse-Design Rug – Size 2.40m x 1.60m
The horse design rug was made to replicate the design on our client’s fabric, featuring simple animal images.
The rug was hand-woven in Nepal using only two colours and made in a 60 knot pile. This rug was one of a pair, the second being in the image of a deer. Our client was thrilled with the end result and the rugs look superb in their surroundings.