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Deckfab Panel Kits

 

 

Supplying custom deck panels from a template

Deckfab offers a tailored solution for those seeking custom deck panels in synthetic teak, crafted precisely from templates supplied by customers. This bespoke service allows for the creation of decking that perfectly fits unique specifications and design preferences. By leveraging advanced manufacturing techniques and high-quality materials, Deckfab ensures that each custom panel not only matches the aesthetic and functional requirements but also maintains the durability and low-maintenance benefits synonymous with synthetic teak. Whether for residential patios or commercial marinas, Deckfab’s custom synthetic teak panels provide a seamless blend of personalized design and practical performance.

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PVC Synthetic Teak Deck Kits

Overview

PVC synthetic teak deck kits are designed to closely replicate the appearance and texture of natural teak wood, featuring a realistic natural grain that is almost indistinguishable from the real thing. These kits are particularly popular in marine and outdoor applications due to their durability and low maintenance requirements.

Manufacturing Process

  1. Material Composition: The kits are made from high-quality PVC, known for its durability and resistance to the elements.
  2. Extrusion: We offer various color options in 20-meter length rolls of PVC extrusions. These extrusions are used to fabricate synthetic teak deck products, providing flexibility in design and application.
  3. Texture and Appearance: The surface texture of the synthetic teak is crafted to have a realistic natural grain, giving it an authentic teak look.
  4. Cutting and Fabrication: The PVC extrusions can be cut and shaped as required. We also provide extrusions for edge margining and wide planks for creating border margins, enhancing the visual appeal of the deck.
  5. Welding Process: Our system involves top and bottom welding on the margins and backwelding elsewhere, ensuring the highest level of durability and structural integrity.

Features and Benefits

  • Realistic Appearance: The natural grain texture and varied color options make PVC synthetic teak deck kits visually similar to real teak wood.
  • Durability: Our synthetic teak deck products are designed to withstand harsh marine environments, including UV rays, saltwater, and heavy foot traffic.
  • Quality Assurance: With 15 years of experience in fabricating decks, we have perfected our production process, making our system one of the most durable on the market.
  • Flexible Application: Available in long rolls and customizable extrusions, our PVC synthetic teak deck kits can be tailored to fit various design needs, including edge margins and border margins.
  • Low Maintenance: Compared to natural teak, PVC synthetic teak deck kits require significantly less maintenance, saving time and effort.

PVC synthetic teak deck kits offer a high-quality, durable, and visually appealing alternative to natural teak wood, making them an excellent choice for enhancing marine and outdoor spaces.

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Steel boat with composite cork deck

 Rubber Deck Kits

Overview

Rubber deck kits are a durable and versatile choice for marine and outdoor applications. They offer a comfortable, non-slip surface that is ideal for environments where safety and durability are paramount. These kits are designed to mimic the appearance of natural teak wood while providing the benefits of rubber.

Manufacturing Process

  1. Material Composition: The kits are made from high-quality rubber with added cork granules, known for its durability, flexibility, and resistance to environmental factors.
  2. Extrusion: The rubber is extruded into sheets, which are then processed to achieve the desired thickness and texture
  3. Cutting and Shaping: The rubber sheets can be cut and grooved to the required shape using precision cutting tools, including CNC machines.  The grooves are then filled with mastic to create the caulking lines.
  4. Adhesive Backing: Rubber deck kits can come with adhesive backing for easy installation but more usually they are adhered using mspolymers, ensuring a strong bond with the surface .

Features and Benefits

  • Durability: Rubber is highly durable and resistant to wear and tear, making it suitable for high-traffic areas and harsh marine environments.
  • Non-Slip Surface: Rubber provides excellent traction, even when wet, enhancing safety on marine decks and other outdoor surfaces.
  • Comfort: The flexibility and cushioning properties of rubber offer a comfortable surface to walk on, reducing fatigue during extended periods of use.
  • Resistance: Rubber is resistant to UV rays, saltwater, and various chemicals, ensuring long-lasting performance and minimal degradation over time.
  • Easy Installation: The installation process is straightforward and does not require specialized tools or skills.
  • Low Maintenance: Rubber deck kits are easy to clean and maintain but it is best practice to protective coat them as part of annual maintenance schedule to keep them looking at their best. Nitrile rubber tends to grey over time similiar to the weathering of teak.
  • Cost-Effective: These kits provide an affordable alternative to traditional teak wood, offering similar aesthetic appeal and functional benefits.

Rubber deck kits are an excellent choice for those seeking a durable, safe, and low-maintenance decking solution that still captures the look of natural teak wood. They are well-suited sailboat cockpit seats.

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Foam synthetic teak

EVA Foam Deck Kits

Overview

EVA foam deck kits are a popular choice for marine and outdoor applications due to their comfort, durability, and ease of installation. These kits mimic the look of natural teak wood while providing additional benefits unique to EVA foam.

Manufacturing Process

  1. Material Composition: EVA (Ethylene Vinyl Acetate) foam is a soft, flexible, and durable material that offers a comfortable and non-slip surface.
  2. Extrusion: The EVA foam is made into sandwich coloured sheets , which are then processed to achieve the desired thickness and texture.
  3. Coloring and Texture: The sheets are coloured to mimic the appearance of teak wood and can be textured with wood grain patterns to enhance the visual effect and provide a more natural look.
  4. Cutting and Shaping: The foam sheets are cut to shape, often using CNC machines for precision. They can be custom-cut to fit specific spaces or sold in standard sizes.
  5. Adhesive Backing: Many EVA foam deck kits come with adhesive backing, making them easy to install. The adhesive ensures a strong bond with the surface, whether it’s a boat deck, patio, or other application.

Features and Benefits

  • Comfort: The foam is soft and comfortable underfoot, reducing fatigue during long periods of standing.
  • Non-Slip Surface: EVA foam provides excellent traction, even when wet, making it ideal for marine environments.
  • Durability: EVA foam is resistant to UV rays, saltwater, and chemicals, ensuring long-lasting performance.
  • Easy Installation: With adhesive backing, the installation process is straightforward and does not require specialized tools.
  • Low Maintenance: EVA foam deck kits are easy to clean and require minimal maintenance compared to natural wood.
  • Cost-Effective: They offer a budget-friendly alternative to traditional teak wood while providing similar aesthetic and functional benefits.

EVA foam deck kits are a practical and attractive solution for those looking to enhance their marine or outdoor spaces without the high cost and maintenance associated with real teak wood.

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