Rugs have been made in Nepal for many years. The industry began with an influx of Tibetan refugees in the 1950’s – many of whom brought with them virtually nothing but their rug making skills. Encouraged by the authorities to look after themselves, they began by selling rugs to the tourists who were starting to visit Nepal at this time.

Almost all the rug making process from the carding of wool to the final washing and drying, is done by hand, thereby creating a considerable number of skilled and semi-skilled jobs.

The rug making method in Nepal is best understood as a specialised form of weaving – and as such, differs from Persian techniques which use individually tied knots. Weaving is done on a vertical loom on which a double warp, usually of cotton, is stretched and tensioned.

Alternate strands of warp are separated slightly fore and aft by a shed stick or heddle rod. Rug making starts by inserting a cylindrical guide rod perpendicular to the warp threads. Starting from the left of the warp, wool is looped behind the first two warp threads and then wound around the guide rod. Before repeating the whole process with the next two warp threads.

The process continues until a whole row across the warp has been completed. The wool-covered rod is then beaten down hard with a special comb. Two weft threads are then woven in, to secure the pile row just completed – and these are then tamped down with the comb to ensure a dense and hard-wearing rug.

The loops around the rod are then cut open along the top of the rod using a sharp knife, creating in the process a double pile tuft. The body of the rug is created by building row upon row of pile tufts. The pattern develops by changing the colour of the wool at critical points.

By varying the thickness of warp and weft threads, the wool yarn and the guide rod, different densities of pile and suppleness can be achieved. Typically these range from 60 tufts per sq inch (6.25 sq cm), to very fine rugs with 100 tufts per sq inch (6.25 sq cm).

After weaving, the rugs are washed, dried and stretched if needed. Some patterns may then require carving to accentuate the design. For other designs, this is not required.