TDS completes the third phase of USS ALABAMA’S teak deck replacement project.
TDS, was appointed by USS ALABAMA Battleship Memorial Park to undertake the task of replacing the 80-year-old teak deck on the iconic WWII battleship. Commencing in November 2021, the ambitious three-year deck replacement project involved meticulous digitization and engineering of the deck, followed by installation which began in February 2022. Today, we proudly announce the successful completion of the third phase out of five, with the new deck expected to be fully completed in July 2024.
Covering an expansive area of 21,000 ft2, the fabrication of the deck is undertaken at TDS’s manufacturing facility in Sarasota. The estimated hours for fabrication are 19,000, while installation demands 21,000 hours of dedicated craftmanship. A highly skilled team comprising of 6-8 members from TDS is onboard the historic battleship, ensuring the installation of the new deck.
With the completion of the third phase, visitors can once again enjoy full access to the starboard side of the WWII battleship USS ALABAMA. As we move forward with the project, a temporary ramp has been placed at the top of the battleship’s gangway for the duration of the project.
To commemorate this significant endeavor and support the teak deck replacement project, visitors can purchase finished items crafted from the worn original planks. Additionally, larger dimensions of the unfinished teak planks are sold by the linear foot by appointment only. All proceeds go directly to the funding of teak deck replacement project.
Richard Strauss, CEO said “It is an honor for all of us at Teakdecking Systems to be entrusted with the responsibility of building and installing a new deck for the legendary USS ALABAMA battleship. This project presents significant challenges, considering that the memorial park remains accessible to visitors, but our team are driven by a deep satisfaction of playing a part in restoring the historic battleship back to its former glory”.
“Replacing our World War II teak deck is a three-year, $8.5 million project. Maintenance of the battleship, submarine and park exhibits is expensive. We work those requirements simultaneously with the teak deck project,” said USS ALABAMA Battleship Commission Chairman Terry Ankerson.
ALL PRODUCTS
How To remove old caulking from your deck and & Re-Caulk your Seams
If you're planning to get a new deck on your boat, and you've chosen teak, a composite deck, or a cork alternative, this guide will walk you through the full process, from digitization and manufacturing to final installation so you’ll know exactly what to expect from start to finish. TEAK DECKS Digital Templating The first stage involves one of our technicians digitially templating the area using the latest in precise measuring technology. Our team digititally templates vessels all around the world. Engineering Our experienced designers are masters of creating beautiful and technically precise decks using CAD construction program, importing data provided by our digital templating team. Our designers’ exceptional ability to create visual symmetry ensures impeccable finishes and beautiful aesthetic decks. Manufacturing TDS panels are manufactured in our factory utilizing jigs that are adjusted to conform to the vessel’s shape. Teak planks of the required thickness and width are carefully hand inspected, scrutinizing each plank for grain orientation, mineral deposits, or imperfections such as a small knot. The planks are placed into the jig in such a way that the finished deck will have a uniform butt joint pattern. Creating a Watertight Barrier A phenolic or fiberglass backing is securely vacuum bonded to the teak, using our own epoxies that guarantee durability, flexibility, strength and reliability. The exceptional bonding strength, ensures your deck stands the test of time. After the epoxy cures, the newly formed panels are removed from the jig, and the seams between the planks undergo routing, cleaning, and caulking. Margin Trim Once the caulking is cured, the final step involves laying out the teak deck and laying all the margin trim. Upon completion, the finished deck undergoes a thorough quality inspection, ensuring it aligns precisely with the template. Transport & Installation The finished deck panels are placed in custom-made crates and then shipped and installed worldwide. Prior to the arrival of the new deck, the old deck is removed. Our installers inspect for any issues such as water intrusion, delamination, or corrosion on the vessel’s surface. If such issues are found, the areas are repaired before the new deck is installed. Caulking & Sanding Once the deck has been bonded to the vessel, it is time to caulk using our own proprietary, UV, and chemical-resistant caulking TDS SIS-440. After curing, the deck is then ready to be sanded. The entire deck is sanded with 36 grit to remove excess caulking, followed by 60 and 80 grit to enhance the look of the deck. COMPOSITE DECKS Digital Templating The first stage involves one of our technicians digitially templating the area using the latest in precise measuring technology. Our team digititally templates vessels all around the world. Engineering Our experienced designers are masters of creating beautiful and technically precise decks using CAD construction program, importing data provided by our digital templating team. Our designers’ exceptional ability to create visual symmetry ensures impeccable finishes and beautiful aesthetic decks. Manufacturing Every composite decking panel is custom made to perfectly fit the areas to be covered. The panels are delivered with completed seam pattern, sanded and ready to be glued down on most structural surfaces. In the case of SeaSole, the deck is installed using the “peel and stick system”. We use a combination of our TDS bedding and bonding adhesive, along with TDS two-part, flexible epoxy fitting glue, to secure the panels in place. The caulking in the seams is our TDS proprietary patented filler, an enduringly elastic, solid rubber polyurethane joint sealant. Our team will first carry out an inspection of the boat to identify the best application method for each area. Quality Control Once the caulking is cured, the final step involves laying out the composite deck and building all the margin trim. Upon completion, the finished deck undergoes a thorough quality inspection, ensuring it aligns precisely with the original template. Installation The finished deck panels are placed in custom-made crates and then shipped and installed worldwide. Prior to the arrival of the new deck, the old deck is removed. Our installers inspect for any issues such as water intrusion, delamination, or corrosion on the vessel’s surface. If such issues are found, the areas are repaired before the new deck is installed. C ORK DECKS Digital Templating The first stage involves one of our technicians digitially templating the area using the latest in precise measuring technology. Our team digititally templates vessels all around the world. Engineering Our experienced designers are masters of creating beautiful and technically precise decks using CAD construction program, importing data provided by our digitizing team. Our designers’ exceptional ability to create visual symmetry ensures impeccable finishes and beautiful aesthetic decks. Manufacturing Every cork decking panel is custom made to perfectly fit the areas to be covered. The panels are delivered with completed seam pattern, and ready to be glued down on most structural surfaces. Our team will first carry out an inspection of the boat to identify the best application method for each area. Creating a Watertight Barrier After the adhesive cures, the seams between the planks undergo routing, cleaning, and caulking. Installation The finished deck panels are placed in custom-made crates and then shipped and installed worldwide. Prior to the arrival of the new deck, the old deck is removed. Our installers inspect for any issues such as water intrusion, delamination, or corrosion on the vessel’s surface. If such issues are found, the areas are repaired before the new deck is installed. We use a combination of our TDS bedding and bonding adhesive, along with TDS two-part, flexible epoxy fitting glue, to secure the panels in place.
Everything you need to know about cork decks As the industry and yacht owners move towards sustainable decking options, we have recently begun working with cork. This decision has been driven by the increasing demand from environmentally conscious customers . As more people prioritize eco-friendly choices in their purchases, cork has emerged as an ideal decking material. Known for its sustainability and numerous environmental benefits, cork offers unique characteristics that not only provide practical advantages but also contribute to a reduced environmental footprint . This makes cork a compelling choice for those looking to make greener decisions. TDS is a distributor for Navicork by Amorim , the world leader in the cork industry , which is leading the marine revolution with cork decks that champion sustainability. With more than 150 years of history, Amorim has made an unparalleled investment in research, innovation, and design, developing a portfolio of products and solutions that set the standard for environmentally responsible decking . Why is cork so environmentally friendly? UNESCO recognizes cork oak forests as one of the 36 most crucial ecosystems globally, highlighting their environmental significance. Cork is one of the most sustainable resources in the world and remains the only truly carbon-negative product on the market. Eco-Friendly & Carbon-Negative One tonne of cork absorbs about two tonnes of CO₂ while producing only 1.6 tonnes during processing. Harvesting cork does not require felling the tree , allowing forests to continue absorbing carbon dioxide. The bark regenerates , ensuring a sustainable and renewable material for generations to come. Lightweight and Durable Cork is significantly lighter than traditional decking materials, 2 to 5 times lighter than teak, reducing overall vessel weight and fuel efficiency. It is highly resistant to wear and tear , making it suitable for high-traffic marine applications. Superior Thermal and Acoustic Insulation Low thermal conductivity (0.065 W/mºK) minimizes condensation, reduces energy loss and keeps decks cool underfoot. The closed-cell structure of cork dampens structural noise , reducing onboard sound levels and acoustic performance. Comfort & Safety Cork’s soft, velvety texture provides superior underfoot comfort , reducing fatigue during long periods on deck. Its natural non-slip properties enhance safety, making it an excellent choice for marine environments. It’s splinter-free and reduces impact injuries compared to traditional hardwood decks. Design Flexibility & Aesthetic Appeal Available in various textures, colors, and patterns, cork decking can be customized to match the design vision of any vessel. Offers a unique aesthetic while still delivering the premium look and feel desired. For more information check our cork decking section