The manufacturing of a tarp involves a series of precise steps, combining design, cutting, heat sealing, and sewing processes. Here's a detailed overview of each stage:
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How We Make Tarps
Designing and Making The Tarp
The first step in making a tarp is designing the layout and dimensions of the tarp. This process begins with determining the required size, shape, and features of the tarp based on its intended use. Designers use specialized computer-aided design (CAD) software to create a digital blueprint, incorporating the necessary reinforcements, grommet placements, and any additional features required for the specific application.
Material Selection:
Choosing the appropriate material is crucial to the performance and durability of the tarp. Common materials include polyethylene (PE), polypropylene (PP), vinyl, canvas, or a combination of these. Factors such as weather resistance, tear strength, UV protection, and weight are taken into consideration during material selection.
Cutting:
Once the design is finalized and the materials are chosen, the cutting process begins. Large rolls or sheets of the selected fabric are spread out on a cutting table. Automated cutting machines or precision tools, such as computer-controlled cutters, are used to accurately cut the material according to the CAD design. This step ensures consistent and accurate dimensions for each tarp.
Heat Sealing:
Heat sealing is employed to join different panels of the tarp together. It is particularly crucial in creating waterproof seams. In this process, the edges of the fabric are overlapped, and heat is applied using specialized heat-sealing equipment. The heat melts the material, fusing the overlapping sections, and creating a strong, waterproof bond. This technique is especially common in tarps made from PVC or vinyl materials.
Sewing:
In cases where heat sealing is not sufficient, or when additional reinforcements are required, sewing comes into play. Industrial sewing machines with heavy-duty threads are used to stitch various sections of the tarp together. For instance, hems and borders may require sewing to add strength and prevent fraying. Additionally, attachment points for grommets and other fasteners are often reinforced with multiple stitches to withstand tension and stress.
Grommet Installation:
Grommets are small, metal or plastic rings inserted into the tarp at specific points to create attachment points for ropes, bungee cords, or other fasteners. After the sewing process, the tarp is fitted with grommets using specialized grommet machines. These grommets enhance the versatility and ease of use of the tarp, allowing for secure and adjustable fastening.
Choosing The Right Tarp Fabric
Nylon Tarp Fabric
Nylon tarp fabrics are lightweight, strong, and highly versatile. They are known for their excellent tensile strength and resistance to abrasion. Nylon tarps are commonly used in construction, agriculture, transportation, and industrial settings, where they endure challenging weather conditions and heavy-duty usage. The majority of Brumleve’s tarps are manufactured from U.S.A made Nylon.
Polyester Tarp Fabric
Polyester tarp fabrics are known for their exceptional durability, UV resistance, and color retention. They have a higher melting point compared to nylon, making them suitable for applications that involve high heat exposure.
Tarp Fabric Weights
Tarp fabric weight is an important consideration as it directly relates to the material's thickness, durability, and tear resistance. Here are some common tarp fabric weights and their applications:
18 oz Tarp Fabric
This weight is considered heavy-duty and is ideal for demanding applications requiring increased strength and tear resistance. 18 oz tarps are commonly used in industrial and commercial settings for covering machinery, equipment, and construction materials, as well as for trucking and transportation purposes.
22 oz Tarp Fabric
Slightly heavier than the 18 oz variant, 22 oz tarps provide even more durability and protection. These tarps are suitable for applications where extreme weather conditions, prolonged use, or exposure to harsh environments are expected. 22 oz tarps are also commonly used in industrial and commercial settings for covering machinery, equipment, and construction materials, as well as for trucking and transportation purposes. Most of the tarps Brumleve’s make use strong and durable 22 oz nylon. Giving the customer peace of mind knowing that if they order a tarp from Brumleve’s it was made to last.
40 oz Tarp Fabric
A heavyweight option, 40 oz tarps are designed for the most rugged and demanding tasks. They are commonly used in heavy construction, industrial sectors, and for long-term outdoor storage of large equipment, providing superior protection against extreme weather and wear.
Duck Cloth Material
Duck cloth, also known as duck canvas, is a strong, durable, and tightly woven cotton fabric. It gets its name from the Dutch word "doek," which means cloth. Duck cloth is available in various weights, with the most common being 10 oz, 12 oz, and 14 oz. The higher the ounce value, the thicker and more robust the fabric.
- Joseph Flach
