Installation Considerations

WHAT TO LOOK FOR IN TEAK DECK INSTALLS OR REPLACEMENTS


Your beautiful teak deck is showing signs of wear. To scrub, oil, sand, or not? These questions haunt all yacht owners who opted to invest in the durability and beauty of natural teak. But while you or your crew have done all you can, it’s time to call on professionals who can repair or replace the teak and bring it back to its former luster. 


The tell-tale signs of wearing teak can include delamination or voids under the deck, cracked battens where the teak meets vertical surfaces, caulking shrinkage, oil spots, water infiltration, thinning of the surface, or just “tired” looking wood.


While looking for a professional to handle the job, Teakdecking Systems, a leader in teak deck fabrication and installation for over 40 years, recommends the following:

Consider This


  1. Know the reputation of the company you choose. A quick online search can show reviews, ratings, or input from fellow yacht owners. Learn from their experience!
  2. Know the quality of the materials the company uses. Plantation, or fast-growing teak, does not have the tight rings of seasoned, long-term old-growth teak, which is stronger, less permeable, and longer-lasting than the cheaper alternative.
  3. Look at projects the company has done, and the workload currently scheduled. Your job could be put in a long queue, and your boat could be out of commission or charter for longer than expected.
  4. Choose a reputable yard and have the work done there so other projects can be scheduled simultaneously. Such cooperative work with various subcontractors will help you get your jobs done more efficiently.
  5. Prepare the job properly: Ensure the area is clean, accessible, safe, and done in a water-tight environment. Water is the enemy when replacing a teak deck—another good reason to choose a yard with covered space.
  6. Important: Check to see if the company you choose has legal teak in their possession or if they are buying your teak when you place your order. 


From The Professionals


Teakdecking Systems’ recent work on a 68′ Sunseeker at Bradford Marine exemplified how to get the job done properly. Approximately 400 sqft, both lower and upper decks needed to be replaced due to water damage. The crew emphasized the importance of ensuring the integrity of the subdeck and preparing the area for work.

“Preparation is the most important part of the job,” says Sal Busacca, a 25-year TDS team member who is out in the field daily, supervising jobs and talking to clients—both repeat and new, educating them on the processes necessary to execute a successful installation or repair. Since people often ask about pricing, Busacca replied, “It all depends on the complexity of the project, what needs to be done and where it can be done, as well as conditions, and time frame. We have relationships with all the yards—they all know us, so that helps simplify a lot of situations,” he adds.


“It all depends on the complexity of the project, what needs to be done and where it can be done, as well as conditions, and time frame.”


Getting Started


Like those at TDS, a good installation team is aware of the importance of preparing a fair, cleaned, and primed surface for the teak to be fastened to.


After the old teak deck has been removed, installers look for any problems, such as water intrusion, delamination, and corrosion on the vessel’s surface. If there is evidence of such, the areas need to be repaired. Once repaired, it may be necessary to have fairings installed to even the surface, so there are no low points for water to accumulate. This is often done on new and old boats, so the deck is perfectly even. On steel or aluminum vessels, the same process applies. Remember, metal needs to be primed before fairing.


Choosing the correct adhesive used during installation is one of the most important steps. TDS uses its flexible, proprietary two-part epoxy that ensures the adhesion of the subdeck and teak deck. The deck is then fastened using either a pressure bar or vacuum bag method. This step must be applied evenly so the adhesive can cure, and the teak can adequately adhere to the subdeck.

THE NITTY-GRITTY


Once the deck has been fastened to the vessel, it is time to caulk. TDS has even developed our own proprietary, UV, and chemical-resistant caulking. Because of these quality features, there is no need for priming, removing one step from the installation process, making TDS caulk a favorite for boat builders. We take great pride in showcasing its strength, durability, and flexibility on every installation.


Ideally, a pneumatic gun should be used to press the caulk into the bottom of the seams. Each seam is then spooned or tooled with a putty knife. After 5-7 days of curing, the deck is then ready to be sanded. It is important to note that the curing time is doubled with the newly popular white or gray caulking, as is the maintenance. First, the entire deck should be sanded with 36 grit to remove excess caulking, followed by 60 and 80 grit to enhance the look of your new deck.

Caulket Teak Deck


Final Take


Over the years, TDS has installed tens of thousands of teak decks, custom teak logos and patterns, such as the compass rose aboard large private yachts, super yachts and smaller custom and production boats like Scout, Cigarette, and Chris Craft. All of Teakdecking Systems’ work and materials are warrantied for one year but will last for many more!

When it is time for a new or refurbished teak deck, call the experts at Teakdecking Systems first—or last. An educated decision will be an easy one.

QUESTIONS? PLEASE CONTACT US

yacht.services@teakdecking.com

941-756-0600

ALL PRODUCTS

By Anella Alcott April 11, 2025
If you're planning to get a new deck on your boat, and you've chosen teak, a composite deck, or a cork alternative, this guide will walk you through the full process, from digitization and manufacturing to final installation so you’ll know exactly what to expect from start to finish. TEAK DECKS Digital Templating The first stage involves one of our technicians digitially templating the area using the latest in precise measuring technology. Our team digititally templates vessels all around the world. Engineering Our experienced designers are masters of creating beautiful and technically precise decks using CAD construction program, importing data provided by our digital templating team. Our designers’ exceptional ability to create visual symmetry ensures impeccable finishes and beautiful aesthetic decks. Manufacturing TDS panels are manufactured in our factory utilizing jigs that are adjusted to conform to the vessel’s shape. Teak planks of the required thickness and width are carefully hand inspected, scrutinizing each plank for grain orientation, mineral deposits, or imperfections such as a small knot. The planks are placed into the jig in such a way that the finished deck will have a uniform butt joint pattern. Creating a Watertight Barrier A phenolic or fiberglass backing is securely vacuum bonded to the teak, using our own epoxies that guarantee durability, flexibility, strength and reliability. The exceptional bonding strength, ensures your deck stands the test of time. After the epoxy cures, the newly formed panels are removed from the jig, and the seams between the planks undergo routing, cleaning, and caulking. Margin Trim Once the caulking is cured, the final step involves laying out the teak deck and laying all the margin trim. Upon completion, the finished deck undergoes a thorough quality inspection, ensuring it aligns precisely with the template. Transport & Installation The finished deck panels are placed in custom-made crates and then shipped and installed worldwide. Prior to the arrival of the new deck, the old deck is removed. Our installers inspect for any issues such as water intrusion, delamination, or corrosion on the vessel’s surface. If such issues are found, the areas are repaired before the new deck is installed. Caulking & Sanding Once the deck has been bonded to the vessel, it is time to caulk using our own proprietary, UV, and chemical-resistant caulking TDS SIS-440. After curing, the deck is then ready to be sanded. The entire deck is sanded with 36 grit to remove excess caulking, followed by 60 and 80 grit to enhance the look of the deck. COMPOSITE DECKS Digital Templating The first stage involves one of our technicians digitially templating the area using the latest in precise measuring technology. Our team digititally templates vessels all around the world. Engineering Our experienced designers are masters of creating beautiful and technically precise decks using CAD construction program, importing data provided by our digital templating team. Our designers’ exceptional ability to create visual symmetry ensures impeccable finishes and beautiful aesthetic decks. Manufacturing Every composite decking panel is custom made to perfectly fit the areas to be covered. The panels are delivered with completed seam pattern, sanded and ready to be glued down on most structural surfaces. In the case of SeaSole, the deck is installed using the “peel and stick system”. We use a combination of our TDS bedding and bonding adhesive, along with TDS two-part, flexible epoxy fitting glue, to secure the panels in place. The caulking in the seams is our TDS proprietary patented filler, an enduringly elastic, solid rubber polyurethane joint sealant. Our team will first carry out an inspection of the boat to identify the best application method for each area. Quality Control Once the caulking is cured, the final step involves laying out the composite deck and building all the margin trim. Upon completion, the finished deck undergoes a thorough quality inspection, ensuring it aligns precisely with the original template. Installation The finished deck panels are placed in custom-made crates and then shipped and installed worldwide. Prior to the arrival of the new deck, the old deck is removed. Our installers inspect for any issues such as water intrusion, delamination, or corrosion on the vessel’s surface. If such issues are found, the areas are repaired before the new deck is installed. C ORK DECKS Digital Templating The first stage involves one of our technicians digitially templating the area using the latest in precise measuring technology. Our team digititally templates vessels all around the world. Engineering Our experienced designers are masters of creating beautiful and technically precise decks using CAD construction program, importing data provided by our digitizing team. Our designers’ exceptional ability to create visual symmetry ensures impeccable finishes and beautiful aesthetic decks. Manufacturing Every cork decking panel is custom made to perfectly fit the areas to be covered. The panels are delivered with completed seam pattern, and ready to be glued down on most structural surfaces. Our team will first carry out an inspection of the boat to identify the best application method for each area. Creating a Watertight Barrier After the adhesive cures, the seams between the planks undergo routing, cleaning, and caulking. Installation The finished deck panels are placed in custom-made crates and then shipped and installed worldwide. Prior to the arrival of the new deck, the old deck is removed. Our installers inspect for any issues such as water intrusion, delamination, or corrosion on the vessel’s surface. If such issues are found, the areas are repaired before the new deck is installed. We use a combination of our TDS bedding and bonding adhesive, along with TDS two-part, flexible epoxy fitting glue, to secure the panels in place.
March 28, 2025
Everything you need to know about cork decks As the industry and yacht owners move towards sustainable decking options, we have recently begun working with cork. This decision has been driven by the increasing demand from environmentally conscious customers . As more people prioritize eco-friendly choices in their purchases, cork has emerged as an ideal decking material. Known for its sustainability and numerous environmental benefits, cork offers unique characteristics that not only provide practical advantages but also contribute to a reduced environmental footprint . This makes cork a compelling choice for those looking to make greener decisions. TDS is a distributor for Navicork by Amorim , the world leader in the cork industry , which is leading the marine revolution with cork decks that champion sustainability. With more than 150 years of history, Amorim has made an unparalleled investment in research, innovation, and design, developing a portfolio of products and solutions that set the standard for environmentally responsible decking . Why is cork so environmentally friendly? UNESCO recognizes cork oak forests as one of the 36 most crucial ecosystems globally, highlighting their environmental significance. Cork is one of the most sustainable resources in the world and remains the only truly carbon-negative product on the market. Eco-Friendly & Carbon-Negative One tonne of cork absorbs about two tonnes of CO₂ while producing only 1.6 tonnes during processing. Harvesting cork does not require felling the tree , allowing forests to continue absorbing carbon dioxide. The bark regenerates , ensuring a sustainable and renewable material for generations to come. Lightweight and Durable Cork is significantly lighter than traditional decking materials, 2 to 5 times lighter than teak, reducing overall vessel weight and fuel efficiency. It is highly resistant to wear and tear , making it suitable for high-traffic marine applications. Superior Thermal and Acoustic Insulation Low thermal conductivity (0.065 W/mºK) minimizes condensation, reduces energy loss and keeps decks cool underfoot. The closed-cell structure of cork dampens structural noise , reducing onboard sound levels and acoustic performance. Comfort & Safety Cork’s soft, velvety texture provides superior underfoot comfort , reducing fatigue during long periods on deck. Its natural non-slip properties enhance safety, making it an excellent choice for marine environments. It’s splinter-free and reduces impact injuries compared to traditional hardwood decks. Design Flexibility & Aesthetic Appeal Available in various textures, colors, and patterns, cork decking can be customized to match the design vision of any vessel. Offers a unique aesthetic while still delivering the premium look and feel desired. For more information check our cork decking section
March 11, 2025
What to expect from TDS when you order a deck Once you have decided to order your new deck from us, we have a process in place to ensure that the whole manufacturing and installation goes as smoothly as possible. With a commitment to transparency and customer satisfaction, we have put together some guidelines outlining the most important key steps from the moment that you commit to a new deck from us. 1. Customer Inquiry, Quotation Process and Formal Quote When we are first contacted by a customer, we ask that they send us photos and a layout of the boat via our contact page on our website so that we can understand their specific requirements. Our team then conducts its own research by reviewing the layout and photos provided, as well as gathering information about your boat. Based on this information, we develop a budgetary quote, and if the customer is satisfied with it, we provide a formal quote. The formal quote outlines all the essential details, including design specifications, materials, price and timelines. It is crucial that you read through this document carefully. Taking the time to review it not only helps you understand what to expect but also gives you an opportunity to ask questions or clarify any uncertainties before signing. Once the quote is acceepted, we issue a pro forma invoice for the templating/digitizing, after which we will organize a date to digitize the deck. Once we have the digital file, our sales and project management teams meet to review both the quote and the digitized layout to ensure that the quoted square footage is accurate. Should there be any discrepancies, we adjust the quote accordingly and will call you to explain the changes. 2. Securing Your Order with a Deposit After both parties agree on the final numbers, we send an order confirmation for your signature and will then send an invoice for 50% of the materials cost and the cost of digitization so that we can begin building the deck. Once the funds are received, we start production, later invoicing for the remaining 50%. Travel costs associated with the digitization are invoiced separately after the activity has concluded. 3. Project Management and Timeline Confirmation We will assigns a dedicated Project Manager to your deck, and they will be your primary point of contact throughout the entire process. Your Project Manager is responsible for confirming the production and installation timeline and ensuring that every phase of the project is scheduled appropriately. They will communicate any updates, answer your questions, and address any concerns that may arise during production. 4. Final Payment and Scheduling Shipment Before the deck is shipped and installed, we require that the full remaining balance is settled and we can then schedule shipment and installation without any delays. 5. Installation You will have received an estimated quote for installation. Once the deck is installed we ask the captain or project manager to walk the deck with our team and get a sign off and release for the deck and then we invoice them for the final amount along with any associated travel, travel time, accommodation and subsistence. We will invoice you the final amount once the installation has been done.
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