How Are Decks Made? Digitization, Manufacturing & Installation

If you're planning to get a new deck on your boat — whether teak, composite, or cork — this guide walks you through the full process: from digital templating and factory manufacturing to final on-vessel installation. Understanding each stage helps you know exactly what to expect from start to finish, and why TDS's pre-manufactured approach consistently delivers a superior result.

Teak Decks

Stage 1 — Digital Templating

The process begins with one of TDS's technicians digitally templating the vessel using the latest precise measuring technology. TDS teams carry out digital templating of vessels all around the world, capturing exact deck geometry as a data file used throughout design and manufacturing.

Stage 2 — Engineering

TDS's designers use CAD software to create technically precise deck layouts from the templating data. Their ability to create visual symmetry ensures impeccable finishes — managing curved margins, king plank configurations, butt joint patterns, and any custom design elements the owner requires.

Stage 3 — Manufacturing

TDS panels are manufactured in the factory using jigs adjusted to conform to the vessel's shape. Teak planks of the required thickness and width are carefully hand-inspected for grain orientation, mineral deposits, and imperfections such as small knots. Planks are placed into the jig so the finished deck will have a uniform butt joint pattern.

Stage 4 — Creating a Watertight Barrier

A phenolic or fiberglass backing is vacuum-bonded to the teak using TDS's own epoxies, which guarantee durability, flexibility, strength, and reliability. After the epoxy cures, the newly formed panels are removed from the jig, and the seams between planks undergo routing, cleaning, and caulking.

Stage 5 — Margin Trim and Quality Inspection

Once caulking is cured, all margin trim is laid out and fitted. The completed deck undergoes a thorough quality inspection to confirm it aligns precisely with the original digital template before shipping.

Stage 6 — Transport and Installation

The finished panels are placed in custom-made crates and shipped worldwide. On arrival, the old deck is removed. TDS installers inspect for any water intrusion, delamination, or corrosion on the vessel's surface — any issues are repaired before the new deck is bonded in place.

Stage 7 — Caulking and Sanding

Once the deck is bonded to the vessel, TDS's proprietary UV- and chemical-resistant SIS 440 caulking is applied. After curing, the deck is sanded: first with 36 grit to remove excess caulking, then with 60 and 80 grit to enhance the surface appearance and achieve the finished look.

Composite Decks

Composite decks follow the same digital templating and engineering workflow as teak, with differences in manufacturing and installation:

• Manufacturing: Every composite panel is custom-made to fit the areas to be covered. Panels are delivered with the completed seam pattern, sanded, and ready to be bonded to most structural surfaces. SeaSole panels use the neoprene peel-and-stick system.
• Adhesives: TDS uses a combination of TDS bedding and bonding adhesive with TDS two-part flexible epoxy fitting glue to secure the panels. Seams are filled with TDS's proprietary patented filler — an enduringly elastic, solid rubber polyurethane joint sealant.
• Inspection: The installation team first carries out a vessel inspection to identify the optimal application method for each area before bonding begins.
• QC and delivery: After curing, the deck undergoes a full quality inspection against the original template, then is crated and shipped worldwide for installation.

Cork Decks

Cork decks follow the same digital templating and engineering process, with manufacturing specific to the material:

• Manufacturing: Every cork panel is custom-made to precisely fit the areas to be covered, with the completed seam pattern, ready to be bonded to most structural surfaces.
• Application inspection: The installation team inspects the vessel to determine the best application method for each area.
• Watertight barrier: After adhesive cures, seams between planks undergo routing, cleaning, and caulking to complete the watertight system.
• Installation: Panels are crated, shipped, and installed worldwide — with the same pre-installation surface inspection and repair protocol used for teak and composite decks.

Frequently Asked Questions

QHow long does it take TDS to manufacture a deck?

Timeline depends on vessel size, complexity, and current production volume. Once templating is complete and the digital design is approved, manufacturing typically takes several weeks. TDS will provide a specific production timeline at the project quotation stage.

QWhat is digital templating and why is it important?

Digital templating uses precision measuring technology to capture the exact geometry of a vessel's deck area. The resulting data is converted into a CAD model used to drive CNC manufacturing. It eliminates manual fitting errors and allows TDS to manufacture decks at their facilities in the US or Spain for installation anywhere in the world.

QCan TDS manufacture decks for any type of vessel?

Yes. TDS manufactures teak, composite, and cork decks for superyachts, sailing yachts, motor yachts, production boats, commercial vessels, and workboats. Vessel size, material, and complexity determine the manufacturing method and timeline.

QWhat happens if the deck does not fit correctly after delivery?

TDS's digital templating and engineering process is designed to produce decks that fit precisely without on-site adjustment. In the rare event of a fit issue, TDS works directly with the installation team and yard to resolve it as quickly as possible.