How Tarps Are Made
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Tarp Fabric Materials
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Making a tarp begins with its base material--the fabric from which it is woven. This fabric may have different properties based on what kind of tarp the manufacturers want, although all tarps are design to be liquid resistant, and the material will probably be waterproof in some. One common source is nylon, which is both cheap and easily available. Others may use the same materials that oilcloths are made from, called polyethylene fabric, another type of synthetic weave created by scientists for its durability and weather resistance. Because these products are made chemically, they can be designed with specific uses in mind, though some tarps may be made of cotton or other natural materials.
If the tarp is manufactured in a factory or assembly plant, then the polyethylene fabric (or other material) may be woven together as part of the process, different strands sewn between each other for the strongest structure possible. These sheets of woven fabric are then cut into sections and made into separate tarps. These cuts may be different depending on what purpose the tarp is meant to fulfill. If the tarp is being made at home, you usually start with base sheets such as pre-coated nylon or oilcloths.
Tarp Weaving and Films
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The tarp is then layered together for heavy-duty use, one piece bound carefully on the top the other (unless a simpler, single-layer tarp is being made). When the two sections are stitched together, a fusing process occurs where the edges are sealed by heat. At home, this could be as simple as an open flame used to melt the edges together, while in a factory, this step is often combined with the precise cutting and sizing of the tarp.
The tarp is then covered with protective films. This can be a several-step process, and if the tarp is to be colored a specific way, such as blue or different types of camouflage, this is the time the color may be applied. Although for some tarps, the colors may have been added before they were cut. Then the films are added, as wells as chemical layers designed to make the tarp even more waterproof. Other qualities may be added, such as a flame retardant.
When making a tarp at home you will not be able to add these chemical layers, so it is best to keep an eye out for nylon or plastic sheets that are already layered--another technique practiced by professional tarp makers.
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Last Tarp Additions
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The tarp is then prepared for its specific purpose, which usually means being cut with a pattern of holes and having grommets or eyelets inserted to protect the holes from tearing. These holes are used to hold rope or stakes so that the tarp can be staked to the ground or bound around an object like the back of a truck. The grommets are made out of metals such as brass and occur at regular distances, such as every 2 feet.
Other tarps can include buckling mechanisms or certain devices made for a specific task. Tarps can be as large as football fields or only a few yards long, coming in shapes as complicated as hexagons or as simple as squares.
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