How our Teak Decks are Made

1

Measurement & Templates

For the customised construction of the teak decks, we start with a digital 3D-measurement of the deck surfaces on the yacht, accurate to the millimetre. Depending on the application, precise templates can also be made by boatbuilding plywood. Whether hand-made templates or digital measurements: in both cases, the new deck layout is then planned in a CAD construction program.

2

Cutting the carrier plate

A 0.8 mm thick and moisture-barrier epoxy resin fibreglass sheet is cut to the shape of the deck and prepared for bonding on one of our special deck building tables.

3

Battens & Margin boards

The individual teak battens and margin boards are cut from hand-selected planks from certified high-quality Burmese teak. We attach great importance to carrying out the entire assembly of the teak wood from the log to the finished batten in-house and under strict quality controls - a deck can only be as good as the material from which it is built.

4

Preparing the bonding

As soon as the material is ready, the technical-chemical processes begin. Bonds that are to withstand decades of weathering require the best materials and the most thorough substrate preparation. In addition to the mechanical preparation of the surfaces through fine blasting and sanding, special solvents and adhesion promoters are used in this stage of the process to achieve the best possible bondings.

5

Joining the parts

The teak deck now takes its shape for the first time on the special deck clamping tables. The individual battens are clamped, bent over the epoxy resin carrier plate and positioned. The carrier plate is also prepared with special chemical bonding agents for optimal bonding, the permanently elastic adhesive is applied and the deck elements are joined together. 

6

Pre-treatment

It takes several days before the chemical processes of bonding are complete and the deck can be prepared for grouting the deck seams. To achieve the best results, all deck seams must be roughened, cleaned and coated with a special bonding agent in several work steps. Only then does one of the most important and life-extending steps follow: The insertion of a bond braker tape.

7

Inserting the bond braker tape

The three-sided adhesion: Although teak has comparatively low swelling and shrinkage behaviour, it can work slightly under changing climatic conditions. The teak deck seams must be able to absorb these compression and expansion forces without separating from the seam side. It is therefore necessary to prevent the sealant from adhering to the three sides. For this reason, we always place a special bond braker tape in all deck seams after the primer has dried.

8

Caulking

Our modern teak decks are pressure-caulked with teak decking systems TDS SIS 440. This material combines the advantages of pulyurethane and silicone and is the best on the market, not only in terms of UV resistance but also durability. In special drying rooms, we allow the sealant to cure optimally over several days under controlled conditions.

9

Surface treatment

Our teak decks are given their finish and surface texture in 3 sanding stages. The choice of the right grit and the sanding direction are two essential factors that influence this stage of the process. After the final fine sanding, our teak decks are ready for installation.

10

Transport & Logistics

With our workshop trucks, we transport our teak decks to our customers all over Europe. Our boat builders travel with this mobile workshop, complete with teak deck, equipped to react flexibly to all eventualities on site. For the transport of very large decks or our teak decks for self-installation, we work together with selected transport agencies.