Deck repairs & replacement
While designing and manufacturing new teak decks for new yachts may be our passion, older yachts and even fairly new yachts often require new decks. This decision is always difficult and normally made only after it is clearly determined that the old teak deck cannot be economically repaired. Once the choice is made the issues of removal of the old teak deck, old sub-decking, old fairing and old fittings must be considered. The new design must carefully consider new techniques to improve the old, give the yacht new life and a new teak deck which will last its overhauled life.
In refit/replacement, just like new construction, Teak Solutions is a “turn-key” provider. In addition to superior technical support which includes 3-D modeling of the as built surface, laser generated fairing using our proprietary light weight fairing epoxy to generate perfect camber and sheer (assuring water drainage) we then offer a bullet proof subdeck which provides both sound, thermal insulation and a stress able surface to attach a teak deck. Our subdeck are constructed of marine grade pressure treated plywood which is edged 75mm around with teak, stud welded and epoxy set. Finally on top we install the highest grade pre-manufactured teak panels normally constructed the full length of the surface. (up to 21 meters in length) Our panels are the best in the industry, built in long vacuum tables, backed using a biaxial stitched fiber glass matt, saturated in our proprietary epoxy panel adhesive. These panels are then set, again using High Pressure Vacuum to the prepared subdeck. Our caulking is also propriety. As the teak decks were constructed from Computer generated templates cut from the 3-D modeling, we now use these templates as protection until delivery. At delivery our team delivers the finished teak deck, signed Auto-CAD supported drawings of the as built surfaces, cleaning/maintenance instructions and a supply of our propriety cleaners. On this day our worldwide 24 month warranty begins.
Older and sometimes even newer yachts suffer from caulk seam failure. When experienced early in the teak decks life, they are often the cause of installation failure or maintenance failures. On older yachts the caulking simply nears the end of its anticipated life cycle and must be replaced. Normally all teak decks must be completely reseamed at the midway point of their life cycle. For example, teak decks designed to last 20 years normally require reseaming at the 8 to 12 year point.
Reseaming should not be delayed. When completed as indicated the teak decks will be “tightened up” significantly, water intrusion into the subdeck and joints will be limited and the structural integrity of the teak deck will be maintained.
Reseaming is job which is much more technically involved than most Captains’ and owners understand. There are issues of voids, corrosion, fittings, fasteners, depth, width, product selection, and required wood replacement to consider. Teak Solutions has teams which specialize in teak deck refurbishment. We are experts at keeping the seam width minimum, cutting to the proper depth, using methods which maintain the structural integrity of the deck, and in the end minimize the amount of top surface which is removed.
The cost of a teak deck reseam is 40 to 50 percent of the cost of a new teak deck. Therefore all considerations must be made to ensure the client receives a refurbished product which will last at minimum 5 to 8 years. If this cannot be achieved, the teak deck should be removed and replaced.
Repair of a teak deck other than reseaming is normally limited to removal and replacement of damaged battens and or trims. Additionally teak deck modification associated with the movement of fittings, furniture, drains and the addition of steps, podiums and other items are also considered repairs.
Teak Solutions personal are experts at surveying and executing repairs to existing teak decks as required. From the selection of matching wood, removal of the damaged areas, installation of the new pieces, caulking, sanding and detailing our teams quickly and efficiently restore any teak deck area to like new or better. We are the company which regularly complete what other consider the “impossible”. Having a fully functional teak shop, ready stock and qualified craftsmen is the key to our success in this area.