How to Recaulk Seams

“I’d rather burn my boat to the waterline before I recaulk seams again,” a boat owner said to our Sales Manager at a recent boat show.

Then the boat owner laughed and said, “Of course, my family and I love the Hylas 54 too much to do this. But I sure did have some frustrations, largely my fault. It was my first recaulking job, and it was a big one with nearly one mile of seams.”


Aged teak deck

At TDS, we understand that it’s a big job. An aging teak deck can have proud caulking. Scuffing a foot on the deck could loosen the caulk. Or tugging on the caulking will easily pull it up. Additionally, if caulk has separated from the teak planking, it will eventually loosen if not repaired. These gaps will trap water and potentially cause damage.


We have perfected the art of caulking and want to share advice to prevent frustrations like those of the owner at the boat show. Here, we provide some time-tested tips, and if you call us, we will walk you through the process. We want your re-seaming project to be a success.


SIS 440 Caulking, a proprietary formulation, expands and contracts with boat movement and temperature changes. Caulk is designed to do this.


Teak naturally wears 0.25 to 0.5 mm/year, which will cause the caulking to become “proud.” So, it is essential to watch the deck as it ages and to perform a light sanding for periodic maintenance. This sanding will remove the proud caulk and keep the teak surface smooth. A smooth teak surface prevents trapping dirt.



BEFORE STARTING TO RECAULK SEAMS TAKE THESE NECESSARY STEPS


1) DETERMINE THE DEPTH OF THE SEAM

Seams should have a depth of 5/16 to 1/2” (8-12 mm)* for recaulking to be successful (and cost-effective). Do not fill shallow seams because there could be adhesion problems.



*Seams sizes could vary with larger and thicker planks.


Seam is too shallow for re-caulking

2) CHOOSE THE BEST LOCATION FOR TO RECAULK SEAMS

Always work under a cover. Ideally indoors for protection from rain or snow. Indoor temperature control will enhance caulk cure time. Ideally, the temperature should be 40-90°F or 5-33°C. If unable to work under a cover, only open as much seam as can be cleaned and recaulked on the same day.


3) SAND THE DECK

Before beginning to recaulk seams, a light sanding of the deck creates a smooth surface so that caulking does not fill any ridges in the teak. This pre-sanding will make the final sanding (after re-caulking) much easier, saving time.


4) REMOVE HARDWARE

Since sanding is required before and after recaulking, the hardware will rest on proud teak if it is not removed.


5) READ THE APPLICATION INSTRUCTIONS ON THE CAULK PACKAGING

Instructions are carefully written to help users (with SIS 440).


REMOVING OLD CAULKING

Remove ALL caulk to prepare clean seams of fresh wood for new caulk. For small jobs, remove caulk with a razor and reefing hook.


RAZOR

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Teakdecking Systems Reefing Hook

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For large jobs, electric tools are better. A Fein tool with a teak caulk removal blade works well. For experienced users, a saw or router can be used.

Fein Tool

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Teakdecking Systems Seam Sander

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Regardless of the tool, work carefully to not gouge the edges of the seams. Then, the seams MUST be sanded, vacuumed, and cleaned with acetone. Fresh, clean wood ensures optimal adhesion.


BOND BREAKER TAPE IN SEAMS

Place bond breaker tape at the bottom of the seam. The tape prevents an adhesive bond of the caulking to the bottom of the seam, allowing movement during caulk expansion and contraction.


Applying Tape

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New Panel Construction with Tape

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FILLING THE SEAMS

The temperature must be at least 40°F (5°C) when caulking. Fill seams with a manual gun, electric gun, or pneumatic gun. Regardless of the gun type, cartridge tip preparation is the same.


Cut the tip of the cartridge at an angle. Then insert a screwdriver to puncture the foil lining. After completing this, squeeze the tip to flatten it. This will help to align the tip with the seam. NOTE: Fully open the tip and foil, or caulk may push out from the back of the cartridge.


Begin application and ensure caulking goes to the bottom of the seam, allowing it to flow upward until crowning above the top of the seam. Smoothly pull the gun along the seam toward the applicator. Avoid starts and stops or changes in direction that may entrap air.

If using a pneumatic caulk gun, do not exceed 80 psi to prevent overriding the plunger and injection air into the caulk.



Immediately after applying the caulking, draw a flexible putty knife over the seam. Apply enough pressure to make sure caulk fills to the bottom of the seam, and then crowns to allow for slight settling. Make sure the seams have no entrapped air after application. Do not disturb the caulking until fully cured.


Apply pressure to fill seam. Be sure that caulking crowns.

Masking the teak before caulking may be done. Place tape 1 mm from the edge of the seam. Note: It will require more pressure to fill the seam with the putty knife with a masked edge.

CURING

Cure time is a function of the cross-sectional dimension of the seam and ambient temperature and humidity. Cold or very dry air will increase the cure time. Caulking cures from the top down at a rate of about 1-2 mm/day with a maximum rate of 3mm/day. Allow at least 48 hours. White and gray will take longer, so please read about these special considerations at https://teakdecking.com/caulk/

SANDING AND FINISHING

Sand using 80-100 grit sandpaper with a soft pad on a grinder. Do not use orbital and belts sanders because they may “dig” into the teak. A Fein tool with a sanding pad is good for the corners. Hand-sanding is required for details that cannot be reached with power tools. Rich brown teak and razor-sharp seams appear as the caulking is sanded away.



If there are gaps, bubbles, or under-filled seams, it is due to improper caulking. The seams were not filled properly or did not cure adequately.


This deck was not sanded before recaulking, making it difficult to sand off the caulking

We want your project to be successful. To recaulk seams, follow these recommended guidelines and read our free 16-page Caulking Guidebook: Teakdecking.com/caulk. Or Call us if you have questions and we will walk you through the process.


Read more articles:

How to Inspect Teak Deck Caulking and Seams

Application Techniques for Gray and White Caulking

What is the Caulk Yield for Teak Deck Caulking

CONTACT TEAKDECKING SYSTEMS

941-756-0600

products@teakdecking.com

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How are decks made? Understanding the digitization, manufacturing and installation process of your new deck

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.

Everything you need to know about cork decks

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

What to expect from TDS when you order a deck

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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