Where is the deck installation performed?

Once a boat owner decides to add or replace a boat deck (in teak or composite), one of the first questions asked is: “Where do you do the deck installation?” The answer may be nearer than expected. (Spoiler Alert: The boat doesn’t have to be at Teakdecking Systems’ Florida or European facility.)

MODULAR DECKING

Teakdecking Systems creates modular decking in sections sized to fit in available transport. Decks longer than the interior length of a standard 40-foot shipping trailer or container are assembled as interlocking sections. So, panels small enough to fit in the transport and be easily handled by the installation crew within the vessel and shipyards’ confines.

Crates of decking panels ready to transport to boat location

GLOBAL SHIPMENT OF DECKING

For nearly 40 years, Teakdecking Systems has shipped modular deck systems and components across the United States and worldwide. A sampling of some of the northern hemisphere deck destinations includes Japan, North America—USA, Canada, Mexico, the Bahamas & the West Indies, England & Scotland, the shipyards of Europe, and Turkey. The southern hemisphere destinations include Fiji, New Zealand, Chile, Ecuador, and Brazil.

SHIPPING THE DECK TO THE BOAT

Since deck installation can be performed near the boat’s location or near where the boat is headed, the Teakdecking Systems’ Traffic Coordinator will arrange the logistics of getting, shall we say, big things to odd places.

MANUFACTURING IN EUROPE

With its recent asset acquisition of Teak Solutions (Barcelona and Valencia, Spain), Teakdecking Systems strengthened its service to the European and mid-Eastern marine industries and their markets. This expansion also reduces delivery times and costs to those markets. (Currency fluctuations can sometimes make this beneficial, and sometimes not.)

Manufacturing teak decking panels in Valencia, Spain

BOAT LOCATION

Boat owners have extensive latitude in selecting a location for a deck replacement or addition, but a suitable facility must be chosen. The primary requirement is that the boat is out of the weather and in a climate somewhere between 45°F and 95°F (7°- 36°C). The reasons for this include (1) allowing the caulking and adhesives to properly cure, (2) enabling the installation personnel to work effectively, and (3) preventing rain or snow from creating damage or delays. Essentially, this is a building, shed, or tent where the boat (and equipment) can be relocated. It is unnecessary to haul the boat for a deck replacement or installation if in-the-water sheds are available that adequately shelter the boat.

Deck installation is well-protected

PERSONNEL

Even more important than the facilities and equipment available are the carpenters hired to perform the work. If a deck replacement is required, the personnel need to know how to properly disassemble the boat to prepare for removing the existing teak. Then they will need to remove the old teak without damage to the vessel. Some owners (often with assistance from crew or friends) will remove the deck hardware (and sometimes the old teak deck) on smaller vessels to reduce the out-of-pocket expenses. This same group will need to reinstall the hardware onto the new teak or composite deck and recommission the boat for sea.

With boatyards and shipyards fulfilling the criteria of facilities, equipment, and personnel, it is prudent to meet with the service managers at nearby boatyards first. Determine if personnel installing the new modular teak decks have marine carpentry skills, along with experience installing modular teak decks. This could limit the available locations to a few boat or shipyards. Teakdecking Systems can provide recommendations. Further, TDS has their own trained and qualified installation technicians available to travel to the site and perform the work.

If a boat or shipyard has one or more qualified carpenters but no experience with modular deck systems, TDS will offer to send a technician to guide and assist the local carpenter(s) through the process. If qualified local carpenters are unavailable, TDS will assemble a complete team to perform the installation. This latter option is standard with large yacht projects in shipyards. The TDS technician(s) travel and subsistence costs are added to the project invoice. So, finding good local boat-building talent can pay for itself.

To find local boat service facilities, contact the Yacht Services department at TDS. For nearly 40 years, decks have been shipped globally, so they typically have suggestions for service in specific locations.

THREE PHASES OF ADDING OR REPLACING A DECK

According to TDS, there are three phases to replacing or adding a teak deck:

Templating (making an exact pattern on your boat for the replacement deck)
Manufacturing and assembly of the deck panels at the TDS facilities
Installation

After deciding to replace a deck (knowing where it will be done and who will do it), the first step of building the deck is to make a template, and this must be performed on the boat for accuracy.

Fortunately, like the installation location, there are multiple options for template making:

Follow Teakdecking Systems’ thorough and easy-to-follow “Template Making Instructions.”. These instructions detail how to assemble a template using 1/8″ plywood and hot glue (similar to making countertop patterns). The instructions explain how to build the pattern in sections to make it easy to crate and ship to TDS. Some owners make their templates. Additionally, a local marine carpenter or TDS technician can fabricate the stick template.
For projects in remote areas or where there is a timeline crunch or other constraints, Teakdecking Systems offers digitally templating services. TDS will send one or two technicians to the boat, depending on the project size, along with the necessary equipment. The process involves digitally capturing the deck’s shape and any internal details to an accuracy of about 2mm. As soon as the information is gathered, the files can be emailed to the TDS factory. There, plywood patterns are CNC cut, enabling the new teak deck(s) production to begin.

Digital Measurement of Deck

This digital system works well for large yachts, particularly those in transit between destinations. For example, a TDS digital templating team spent several days digitizing aboard a large sailing yacht anchored in the Caribbean shortly after arriving from Europe. Several months later, the new TDS teak decks traveled by container to meet the yacht halfway around the world in New Zealand for their installation. They fit perfectly.

After templating, the decks are built and shipped to the boat’s location for installation. So, while there are many good reasons to take a boat to Sarasota, Florida, adding a Teakdecking Systems modular teak deck system doesn’t need to be one of them. But TDS always welcomes visitors to the manufacturing facility.

MORE INFORMATION

To learn about the cost of installation, please read: How Much Does a Teak Deck Cost – Part 3 of 3: Installation

QUESTIONS

Call 941-756-0600

yacht.services@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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