All deck areas would be digitally measured so as to provide an accurate pattern from which to start designing the deck layout. Using the latest laser and scanning machinery Modesty’s measuring system enables them to produce panels of astonishing accuracy. This obviously speeds up dramatically the installation process and means that the man power they require on site is kept to a minimum.
Once Modesty have the digitalised outline of the deck areas they would then complete the perimeters of the various levels and make any adjustments that may be necessary for the camber of the vessel. Once completed Modesty would start with the marking out the plank runs, king-planks and margin boards. This is done in close consultation with the relevant members of the owner’s team so as to come up with the best options for each individual project.
The design then would be separated into the various panels and all the individual margin boards so as to be cut using CNC machinery. Once these panels and the patterns cut they would then go across to the manufacturing area where the teak panels will be produced. Each individual teak panel is constructed within a mould thus enabling them to slot together perfectly when fitting on board. The teak panel that has been laid up is inspected and then prepared for the gluing process. Once the teak has been prepared, a GRP backing sheet is laid into position and then this ‘sandwich’ is pressed together on the benches by our vacuum bagging technique. These panels are laid up on custom-built benches up that have been prepared for a vacuum bagging system. This is left in place for a minimum of 12hrs i.e. overnight after which time it is removed from its mould. The caulking seams are then cut by CNC to the depth previously agreed and then the agreed caulking compound is tooled into the seams, after the appropriate tapes and primers have been applied.
This is the stage where the full advantage of Modesty’s system comes into play as the installation speed and finished quality of the end product is truly astonishing. Once the panels have been dry fitted they would be ready to be laid down onto a polyurethane bedding compound and then be pressed into situ with a vacuum system. This is intrinsically the same method used to produce the panels in the workshop but with a mobile system which means that the pressure applied throughout all the processes of both the deck build and lay is over every square cm of surface area of the deck area. Once the panels have been fitted together and bonded into place all remaining seams between the panels are cut and caulked in preparation to the final sand and the teak to paint caulking seam applied.