Yacht Deck Refit Timeline

One of the most common questions from owners and captains planning a deck refit is: how long will it take? The honest answer depends on several factors that vary for every project. Understanding the key phases — and what drives the timeline — allows owners to plan the refit into the vessel's schedule without surprises.

Refit Phases and Typical Durations

Phase-by-Phase Detail

Phase 1 — Consultation and Survey

The refit begins with a project consultation to establish scope, material choice, and logistics. For projects requiring a formal deck survey — assessing adhesive bond integrity and substrate condition — a TDS representative or approved surveyor attends the vessel. Survey findings determine whether substrate preparation is required before the new deck can be installed. Schedule this as early as possible to avoid delays in subsequent phases.

Phase 2 — Digital Templating

TDS's templating team visits the vessel to capture the deck geometry using laser measurement equipment. A 60-foot yacht typically takes 1–2 days. A large motor yacht or superyacht may require 3–5 days. Templating can be carried out afloat or hauled. The digital file drives all subsequent manufacturing — its accuracy directly determines panel fit.

Phase 3 — Panel Manufacturing (Off Vessel)

This is the longest phase and the most critical scheduling consideration. Manufacturing time depends on deck size, material, and the current TDS production schedule. A sailing yacht deck set may take 3–4 weeks in manufacturing. A superyacht or multi-deck motor yacht project may require 6–8 weeks. Critically, this entire phase runs with the vessel free — the boat does not need to be in a yard.

For a refit planned for May, templating should ideally be completed in February or March. Owners who leave this phase until the vessel is already in the yard will find the refit is driven by manufacturing lead time, not installation speed.

Phases 4–5 — Deck Removal and Substrate Preparation

The existing deck is removed mechanically and chemically. Adhesive residue is ground back and the substrate is inspected. Condition varies significantly — a deck in good bond condition may take 3–5 days to remove on a 60-foot yacht. An old deck with challenging adhesive or substrate damage requiring remediation can take 2–3 weeks. This variability is why a pre-project survey is valuable.

Phases 6–7 — Installation and Finishing

Pre-manufactured panels are bonded to the substrate using TDS marine adhesive systems. Panel numbering ensures systematic installation sequence. After bonding and cure, final seam work is completed and the deck is inspected. Installation time for a 60-foot sailing yacht is typically 5–10 days; a large motor yacht or superyacht installation may take 3–6 weeks.

Indicative Total Timelines by Vessel Size

• 40–50 ft sailing yacht, straightforward substrate: 5–8 weeks from templating to handover
• 60–80 ft motor yacht: 8–14 weeks from templating to handover
• 30m+ superyacht: 4–6 months from first consultation to handover
• Urgent refit: Contact TDS directly to discuss expedited options for specific situations

How to Plan Your Refit Schedule

The most effective refit planning works backwards from when the vessel must be operational:

• Fix the latest handover date — when must the vessel be ready?
• Subtract installation, finishing, and cure time → latest date to begin installation
• Subtract manufacturing lead time → latest date for templating
• Subtract survey, consultation, and scheduling time → earliest project start

Contact TDS as early as possible. Manufacturing lead times are fixed and cannot be compressed by late project initiation. Owners who contact TDS 4–6 months before their intended refit window have the most scheduling flexibility.

Frequently Asked Questions

QHow long does a full yacht deck refit take from start to finish?

A full deck refit typically takes 6–14 weeks from initial consultation to handover, depending on vessel size and deck complexity. A 40–50 foot sailing yacht with a straightforward substrate may complete in 5–8 weeks. A 60–80 foot motor yacht typically requires 8–14 weeks. Superyacht projects can run 4–6 months or more. The manufacturing phase (3–8 weeks) is the longest single stage and runs off-vessel — the key is initiating it early enough that it does not create a yard schedule constraint.

QDoes the yacht need to be in a yard for the entire refit duration?

No — this is one of the most important advantages of TDS's prefabricated panel process. The vessel is required in the yard only for templating (1–2 days), deck removal, substrate preparation, and installation. Panel manufacturing (the longest phase, 3–8 weeks) takes place at the TDS facility with the vessel free. A well-planned refit minimises total yard time significantly.

QCan part of a teak deck be replaced rather than the whole deck?

Yes. TDS regularly provides partial re-deck services — templating and manufacturing replacement panels for specific areas, sections, or deck zones. This is often the right approach when a deck survey shows that some areas are in good condition and others have deteriorated. Partial replacement is also appropriate after localised damage or when a specific deck area (swim platform, cockpit, foredeck) requires renewal ahead of the full deck.

QDoes composite decking installation take the same time as teak?

Panel installation time is broadly similar for teak and composite — both use the same CNC-prefabricated panel system, the same digital templating process, and TDS adhesive bonding. Composite has no separate caulking phase after installation (seams are integral), which can reduce finishing time slightly. Manufacturing lead time may vary by material and current production schedule.

QWhat happens to the old teak deck when it is removed?

Old teak is mechanically removed from the substrate, cut into manageable sections, and disposed of according to the yard's waste procedures. In many cases, removed teak is recycled or repurposed. The substrate is then cleaned of adhesive residue by grinding and chemical treatment before inspection and new deck preparation begins.

QHow far in advance should I contact TDS to schedule a deck refit?

As early as possible — ideally 4–6 months before the planned refit window. Manufacturing lead time is fixed and cannot be compressed without compromising quality. Owners who contact TDS well in advance have the most flexibility to plan the refit around the vessel's schedule rather than the other way around. For urgent projects, contact TDS directly to discuss what options exist.