What makes a sofa different
A sofa is an armchair stretched to two or three metres, and that length changes everything. The front and back rails span a long distance and need a centre support, a stretcher and often a sixth leg. The seat suspension, whether sinuous springs or webbing, has to stay even across several seats. Seat and back cushions are made separately and must match each other in shape, firmness and shade. Sectional and modular sofas add connectors that must line up between pieces made on different days.
Most export sofas ship with the legs removed and screwed in by the customer, into threaded inserts or leg plates in the frame. Sofa beds and recliners add a folding or motorised mechanism inside the frame.
What we check on a sofa
| Check | How it is checked | What fails |
|---|---|---|
| Frame and centre support | During production: rail sizes, joints, centre stretcher and support leg against the construction sheet. Finished: inspector sits at each seat and at the centre | Missing centre support, creaks, a rail that flexes, joints that move |
| Suspension | Seat pressed at each position; springs or straps counted through the dust cover if agreed | Dips at one seat, uneven firmness, fewer springs than specified |
| Cushions | Zips opened; foam grade, thickness and wrap checked; fibre-filled backs checked for even fill; cushions swapped between positions | Lower-grade or thinner foam, lumpy or short fill, cushions that do not fit their position |
| Fabric | All cushions and modules from one sofa laid side by side against the swatch | Shade differences between panels, pattern not matched across cushions, nap running different ways |
| KD legs | Legs fitted from the hardware pack; each turned fully home | Cross-threaded inserts, legs that wobble, wrong leg length |
| Modules and connectors | Sectional pieces joined; seat heights and arm lines compared | Height steps between modules, connectors that do not engage |
| Mechanisms | Sofa beds opened and closed; recliners cycled; power units run | Stiff or noisy action, pinch points, mechanism rubbing the fabric |
Common sofa defects
| Defect | Usual class | Why |
|---|---|---|
| Frame fails under seated load; finger trap in a recliner or sofa-bed mechanism | Critical | Injury risk |
| Fire label missing or for the wrong market | Major or critical, as agreed | Goods cannot be sold |
| Seat sags or dips at one position | Major | Noticed within weeks of use |
| Foam or fill not as specified | Major | Comfort and lifespan |
| Shade or pattern mismatch between cushions or modules | Major | Visible in the room |
| Leg insert cross-threaded or missing | Major | Customer cannot assemble |
| Loose threads, small marks, uneven piping | Minor | Cosmetic |
Rules that apply to sofas
- United States. 16 CFR 1640 (TB 117-2013) covers sofas, sectionals and recliners, including the upholstered decking under loose seat cushions. Each piece needs the permanent federal label; California adds its notice. Power recliners fall under UL 962, which covers motor-operated furniture; see UL and ETL listing.
- United Kingdom. The Furniture and Furnishings (Fire) (Safety) Regulations 1988 cover sofas, sofa-beds and futons: compliant fillings and covers, and a permanent label.
- European Union. Textile fibre labelling for covers at least 80% textile by weight; REACH limits on chemicals; the GPSR for general safety and traceability.
- California. Prop 65 warnings where foam, fabric, leather or finishes contain listed chemicals.
Smolder and ignitability tests are lab tests on the materials. On site we check that production fabric, foam and barrier match the test reports and that every label is present and permanent.
Carton compression and transit damage
Sofas are packed in large, light cartons, and other cartons are often stacked on them in the container. If the carton is too weak, the sofa itself carries the load above it: arms crush, back cushions flatten and fabric creases. The inspector checks carton grade against the specification, corner and arm protection, and whether cushions are in the carton or compressed and bagged. A sample carton is drop-tested, then the sofa is unpacked and checked for frame damage and crease marks.
Sealed poly bags trap humidity; the inspector checks that frames and cushions are dry before bagging. The hardware pack for legs and connectors must be fixed in a marked place. At loading, container loading supervision checks the stacking height and that heavy cartons are not put on top of sofas.
What to put in your purchase order
- A construction sheet: frame material, rail sizes, centre support, suspension type and count.
- Foam grade, thickness and wrap for seat and back; fill type and weight for fibre cushions.
- Fabric swatch, shade tolerance, pattern matching rules and direction of nap.
- Leg type, length, finish and fixing; connector type for sectionals.
- Fire and law labels for each market, and current test reports for each material.
- Carton grade, maximum stacking height and the drop-test procedure.
- Overall depth and height, so the sofa fits through a doorway in its market.
See pricing and our sample reports for the report format.