All deck areas are digitally measured to provide an accurate pattern from which to start designing the deck layout. Using the latest laser and scanning machinery our measuring system enables us to produce panels of astonishing accuracy. This obviously speeds up dramatically the installation process and means that the manpower required on site is kept to a minimum.
Once we have the digitalised outline of the deck areas, we then complete the perimeters of the various levels and make any adjustments that may be necessary for the camber of the vessel. Once completed we start with the marking out of the plank-runs, king-planks and margin boards. This is done in close consultation with the relevant members of the owner’s team to ensure the best result for each individual project.
The design is then separated into the various panels and all the individual margin boards ready to be cut using our CNC machinery. Once the panels and patterns are cut, they go across to the manufacturing area where the panels are actually produced. Each individual panel is constructed within a mould thus enabling them to slot together perfectly when fitting on-board. Each panel that has been laid up is inspected and then prepared for the gluing process. Once the panel has been prepared, a GRP backing sheet is laid into position and then this ‘sandwich’ is pressed together on the custom-built benches that have been prepared for vacuum bagging. 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. The installation speed and finished quality of the end product is extraordinary. Once the panels have been dry fitted, they are 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. This means that the pressure applied through the processes of both the deck build and the deck laying, is the same, and is over every square centimetre 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 for the final sand and the wood to paint caulking seam applied.