Prefabricated teak deck panels
Your templates go out. A finished deck comes back.
Specifications
ONE-OFF AND SERIES
| Teak thickness | 6, 8, 10, 12, 16 and 20 mm |
|---|---|
| Plank width | 30–90 mm |
| Frame width | 30–150 mm |
| Caulk seam | 4–5 mm |
| Maximum panel size | Set by transport |
| Caulk | TDS or Zetamarine, in black, grey or white |
| Adhesive | Two-part marine epoxy or MS polymer |
| Lead time, one-off | 5–10 weeks, project-dependent |
How the process works
Templating, or your own templates
We take the deck digitally on site, or you send templates you have made yourself to our guidelines, or your own drawings as DWG or DXF files.
CNC cutting and assembly
Planks are cut to the vessel’s geometry and assembled into panels sized for transport and fitting.
Caulking, sanding and finishing
Seams are filled, cured and sanded flat in the workshop, where conditions are controlled.
Packing and delivery
Panels ship flat, protected, with the bonding specification your team follows on installation.
01
What a prefabricated teak panel is
A prefabricated panel is a finished section of deck, built flat in a workshop and delivered ready to bond down.
Inside it, the teak planks and the caulk seams are the same as on a traditionally laid deck. What is different is that they are assembled onto a flexible backing rather than fitted plank by plank onto the boat, and that the caulking and the first sanding happen indoors, at a known temperature, on a bench.
The panel is cut to your vessel’s geometry, not to a standard size. Margins, king plank, covering boards, hatch surrounds and the run of the planks are all decided before anything is cut, from a template of that boat.
What arrives is a set of numbered panels, packed flat, with the bonding specification for your substrate. Fitting them is bonding, trimming at the fixed edges, and a final pass over the joins.
The trade is straightforward: almost everything gets easier, and the template has to be right. A panel is cut to the template rather than to the boat, so a measuring error is reproduced exactly and at full size. Everything else on this page follows from that one fact. How templating works.
02
Backing and substrate
The panel needs something sound to bond to, and that is the part of the job nobody can assess from a distance.
On a laminate deck we are looking for moisture and delamination, particularly around old fastener holes and fittings. On steel or aluminium, for the coating system and its condition. On a timber deck, for what is underneath the old fixings. In every case the substrate has to be clean, dry, faired and structurally sound before adhesive touches it.
Where a deck is being replaced, that assessment happens with the old deck off, the only point at which it can be made honestly. On a new build, your own build specification governs and we work to it.
03
Lead times and delivery
Five to ten weeks from approved templates for a one-off deck, depending on the project. Series production is scheduled by arrangement with the yard.
Panels travel flat as freight, which is what makes distance workable: the templates move as data, and only the finished deck is shipped.
The clock starts at approved templates, not at order. Where a survey has to happen first, or where an old deck has to come off before the geometry can be taken, that time sits in front of the lead time rather than inside it.
04
Series production for boat builders
For a yard building the same hull repeatedly, the first set is the project and every set after it is a delivery.
We build and approve one deck against your specification, then produce from the same programme, as long as the hulls are. Series production depends on how accurate the yard’s moulds are. Where the hulls come out of the mould without deviation, the panel sets are identical hull to hull (same thickness, same seam, same plank run), and your fitters learn the deck once. Where they deviate, we measure each vessel separately and build to it.
Scheduling works backwards from your build slots rather than forwards from our order book, and the documentation that follows each set is identical, so a compliance file does not have to be rebuilt per hull.
Series pricing is per set, and depends on volume and commitment rather than on the size of any single order.
Send us your templates
Tell us the boat and what it needs. We quote per vessel, not from a price list.
