Dek-King Installationsanleitung

Dek-King Fitting GuidesDek-King Fitting Guides

Version: March 2012

Woodrolfe Road · Tollesbury · Essex · CM9 8RY · EnglandTel: +44 (0)1621 869609 · Fax: +44 (0)1621 868863Email: [email protected] · Web: www.wilks.co.uk · www.dek-king.com

Woodrolfe Road · Tollesbury · Essex · CM9 8RY · EnglandTel: +44 (0)1621 869609 · Fax: +44 (0)1621 868863Email: [email protected] · Web: www.wilks.co.uk · www.dek-king.com

INDEXForeword ................... .......................................................... Page 1Introduction .............................................................................. Page 2Chapter 1 - Fitting directly to a deck ............................. Page 6Chapter 2 - Templating .......................................................... Page 9Chapter 3 - Fabricating mats from templates .......... Page 11Chapter 4 - Installing prefabricated mats .......... Page 18

Disclaimer

All dimensions and information shown in this brochure are to our knowledge correct at the time of going to press. They are subject to our normal manufacturing tolerances and any modifi cations that we feel are necessary. Whilst we have endeavoured to ensure that the information given herein is true and reliable it is given only for the guidance of our customers. It is the user’s responsibility to ascertain the suitability of products by their own tests.

“Wilks” and “Dek-King” are registered trade marks of WIlks (Rubber Plastics) Mfgs Co Ltd.

No part of this catalogue may be reproduced without the express permission of Wilks (Rubber Plastics) Mfgs Co Ltd.

Foreword

www.wilks.co.uk · www.dek-king.com Page 1

Wilks is proud to be one of the world’s leading companies in the manufacture and supply of impact protection and decking systems.

Since 1973 we have supplied many leading boat builders with their profi les and our customer base spans the globe.

We manufacture a wide range of fendering profi les for both boat and pontoon applications as well as accessories for other marine users including Dek-King®, a superb alternative to teak decking.

At our premises we hold a vast stock of profi les in fl exible PVC, rigid PVC, PVR, stainless steel, aluminium and rubber; but as manufacturers we can also supply to meet your individual trade requirements.

If you are unable to fi nd what you need then please do not hesitate to contact us to discuss your exact requirements. Our in-house tooling facitities ensure that we are able to off er our customers full support from the early stages of product development through to manufacture. We can also extrude custom-made profi les to your specifi c colour requirements with extremely reasonable order quantities.

Introduction


After consulting with our fi tters we have pooled our collective knowledge together to form a step-by-step instruction manual to act as a guide for the fi tting of our range of Dek-King products.

We have covered the main types of methods that would be encountered during a typical fi t:

• full fi t directly to a deck

• the templating of an area in preparation of fabrication mats

• the fabrication of mats from templates

• the installation of mats to a prepared deck

The techniques detailed will help ensure that our products are used and fi tted in the correct manner in order to provide the best performance possible.

Should you require clarifi cation on any steps of the process then please do not hesitate to contact our sales team who will be happy to disuss them further.

Disclaimer

All information within this brochure is to our knowledge correct at the time of going to press. The instructions detailed herein are purely for guidance purposes only and it is the user’s responsibility to ascertain best working practise before undertaking any works.

“Wilks” and “Dek-King” are registered trade marks of WIlks (Rubber Plastics) Mfgs Co Ltd.

No part of this catalogue may be reproduced without the express permission of Wilks (Rubber Plastics) Mfgs Co Ltd.

Introduction

www.wilks.co.uk · www.dek-king.com

IntroductionDek-King by Wilks is the ultimate alternative to teak decking and can be easily fi tted by the amateur and professional alike. Simply join the Dek-King strips together using the tongue and groove joint and Stelmax adhesive to create a continuous area of decking ready to be adhered to your deck. The material used for Dek-King is of an outdoor grade PVC that is UV stabilized and contains a colour fast pigment and inbuilt graining eff ect that is totally convincing and will therefore retain its classic looks for many years. Combined with the integral dark caulking edge and tongue, the result will look like a traditional craftsman laid deck.

Page 3

Some of our popular sections, please see our product pages for full details.

Profi lesA range of profiles are available, see our product pages for detailed information. The profiles are finished with a non-slip surface and the underside has a ‘Scotchbrite’ finish allowing the adhesive to bond firmly with the Dek-King and deck. Dek-King can be fixed to almost any surface including GRP, Steel and Timber.

Extrusions are generally supplied in 2.25m lengths and 10m coils.

9 x 2.25m lengths will cover 1 square metre

1 x 10m coil will cover half a square metre

Dek-King weighs approximately 6kg per square metre.

Introduction


Examples of profi le usage

Page 4

Introduction


AdhesivesWe supply two types of adhesive, Stelmax and Sealtack 750. Stelmax adhesive is used to join the strips of Dek-King together and is supplied in a 135ml tube that will bond approximately 2 sq m of tongue and groove joint.

Sealtack 750 is a high tack MS-Polymer adhesive used to bond Dek-King to the required surface and has a shelf life of 15 months in unopened packaging. Sealtack 750 is supplied in 600ml Sausages that will bond approximately 0.6 sq m of Dek-King. The minimum working temperature is 10°C and will be tack free after approximately 4 hours, load bearing strength in 12-24 hours and full strength in 2-3 days.

We recommend that protective clothing, gloves and safety goggles are used when applying adhesives.

Tools requiredCraft Knife Dek-King Cutters Steel rule Steel Set Square Tape Measure Masking Tape Marker Pen Pencil Adhesive Applicator gun Adhesive Spreader Extendable Roller Hot Air Gun

PreparationAll surfaces should be made sound and be as flat as possible, any irregularity in deck levels should be filled and smoothed, as any difference in deck levels will show after laying the decking, after sanding ensure that all surfaces are dry and free from dust. A working temperature of 10°C to 25°C is required. Dek-King should not be laid in wet or damp conditions as this will affect the adhesive bond. It is advisable to unroll the 10m coils of WDK 108 and either lay flat for 24 hours prior to use or re-coil them with the black caulking strips facing inwards. This ensures that the profile is flat when fitted.

General care and maintenanceOnce your deck has been laid it will only require minimum maintenance. A general wash with soap and water will remove most stains. A power washer may also be used, an advantage over teak. Should your Dek-King receive any surface damage this can be rectified by using a 40 Grit paper, sanding by hand in line with the grain. Large belt sanders are not recommended as they tend to be too industrious for the job, more effective results are achieved by sanding one plank at a time. If a section of Dek-King is badly damaged it is possible to remove a section and replace with new Dek-King.

Do not use Acetone on the Dek-King product, as this could result in permanent damage. Be very careful if cleaning your decks with Acetone prior to adhesion.

Chapter 1 - Fitting directly to a deck


Margins and King PlanksHaving decided on the type of margin you would like to use (WDK103, WDK102 or WDK100) you now have to cut and dry lay the margins including King Planks (WDK106), hatch corners and deck margins as shown below. A hot air gun may be used to help the DEK-KING® bend to follow the outer curve of the deck.

When the margin is dry laid scribe a line along the deck following the margin edge, tape this edge so that any excess adhesive is easily removed before the next operation, the same procedure applies for the King Plank. Apply the adhesive, lay the Dek-King margin and King Plank removing the tape and excess adhesive.

Page 6

Filling in straight runsOnce the margins and King Plank have been laid the remainder of the Dek-King can be fi tted. This can be achieved by joining lengths of Dek-King (WDK100 0r WDK108) together to form a mat that can be laid in one operation. Each joined mat should be between 1 & 2 sq metres. Any larger than this will be diffi cult to adhere in one go. For example the area below has been fi tted in a total of 5 sections.Start at the centre of the area and work out towards the sides, creating as many sections as practical for adhering to the substrate. Join the planking together in the appropriate sections using Stelmax 1985. Allow to cure for an hour before rolling up ready for bonding to the deck. Using an applicator gun, apply to the area below the mat being careful not to use too much, more can be added later if required.



Using a spreader, apply evenly over the entire area ensuring a good coverage and aiming for approximately 3mm grooves at right angles to the run of the main plank area as this will ensure eff ective adhesion. Keep the Dek-King weighted after rolling – It is advisable to weigh down the mats with tubs or containers fi lled with sand or water and using wood planking to spread the weight as required over larger areas.

Note. Be careful if using water – although the adhesive is moisture curing it is best left for a couple of days before getting really wet.

Filling in swept runsOnce you have your inner and outer margins adhered you can begin on the infi ll using either WDK100 or WDK108. At this stage it is not recommended to adhere the king plank. This is because boats are often not exactly equal in width from side to side and you may discover that the true centre of the boat is diff erent from the ‘visual centre’ required to create the perfect fi nish. Run the fi rst infi ll plank, tongue to outer perimeter margin groove, and cut it in as required around fi ttings or simply at each end. At the forward end cut the plank a couple of inches past the centre line as this will be fi nished later. Once you have ‘dry cut’ the side decks you will need to decide how many sections you will be able to manage when adhering to the deck. Join the planking together in the appropriate sections using Stelmax 1985.

Allow to cure for an hour before rolling up ready for adhesion to the substrate.

Page 7

King Plank FittingThis operation is done with the King Plank adhered to the deck and the adhesive set. Now that the side decks are adhered you will be able to take ‘visual centre’ from the run of the planks. Measure across the widest point, to the inside edge of the decking running through from the side decks. The prow of the boat will give you visual centre for the top of the king plank. Adhere the king plank to the deck and allow to cure for 2 hours. The infi ll plank, WDK 100, needs to be marked where the top edge intersects with the King Plank (‘A’). From this point measure 20mm at right angles in towards the centre of the infi ll plank (‘B’) and mark. From this mark scribe a line to where the bottom edge of the infi ll plank intersects the King Plank (‘C’), draw a line to connect ‘A’, ‘B’ and ‘C’, this will give the correct shape. Before cutting, decide at this time if you wish to give the angles a radius for a stylish shape. Having cut the end to shape now draw the end shape onto the King Plank as a guide line. You now have to measure 5mm from the guide line towards the centre of the King Plank, this will be the cutting line and should leave a 5mm gap between the end of the infi ll plank. Remove the section of King Plank with a Craft Knife and chisel for the part adhered to the deck. The 5mm gap will eventually be fi lled with Sealtack 750 adhesive.



Hatch Corners and Curved CornersFitting around hatch corners can be achieved by fi rst taking a template of the corner to be cut (Fig 1). Use this template to cut out the corner shape from the King Plank and then adhere the ‘T’ Caulking to the inside edge of the corner (Fig 2 & 3). Cut all corners from the King Plank (WDK 106 or WDK 112) and infi lls from the WDK 100 or WDK 108 you may have to remove the tongue from the WDK 100. Cut the required length of ‘T’ Caulking (Fig 4). Join all components together using Stelmax (Fig 5). Note that in fi gure 5 the base of the ‘T’ Caulking has been mitred to help fi t the bend of the corner. Normal deck runs can then be laid in the normal way up to the hatch (Fig 6).

Page 8

(Fig 1) (Fig 2)

(Fig 3) (Fig 4)

(Fig 5) (Fig 6)

Chapter 2 - Templating


Tools requiredDurable, non stretch material that will allow you to trace the area (waxed craft paper is ideal)

High tack double sided tape

Permanent Marker Pen

Sharp knife

InstructionsClear area to be templated. Cut 5cm pieces of tape and stick down every 60cm or so around the edges of the area to be templated, leaving the backing paper in place for the moment.

Using a sharp knife, roughly cut the templating material to size leaving some overlap at this point.

Lay the templating material over the area to be templated and hold in place with weights if required. If it is a large area the templating material may need to be joined together. To do this use the double sided tape, leaving an overlap of 8-10 cm.

Page 9

Working around the area to be templated, peel off the backing paper from the tape and stick the template material down, keeping it fl at and taut. Once you have worked your way around the area, adjust the template material as required to ensure it is all fl at and taut as accuracy in templating is important to the fi nal fi t of Dek-King (See Fig.7) .

(Fig 7)

Chapter 2 - Templating


Using a permanent marker draw an outline of the shape required. Ensure you mark where any existing deck fi ttings are and whether you would like these to be cut out or if the decking will run underneath these areas (See Fig 8).

Page 10

Generally if a fi tting is more than 5mm in height it should be cut around and if less than 5mm in height it should be fi tted on top of the Dek-King. However, if a fi xture is load bearing e.g. a bollard, it should be fi tted to the deck and cut around.

It is important to mark the direction of the planking and particularly how any individual panels will sit together. This is to allow the planking to be aligned over the whole area and these can be labelled as appropriate. Also label edges with ‘Straight’ edge or ‘Margin’ whichever is preferred and also label any corners ‘Rounded’ or ‘Mitred’ whichever is preferred (Fig. 9)

If templating side decks please ensure the template is marked ‘Port’ or ‘Starboard’.

(Fig 8)

(Fig 9)

Chapter 3 - Fabricating mats from templates


Curved or Radius MarginsClear your working area and lay out your template ready (See Fig 10)

Page 11

(Fig 10)

When making a mat to fi t a template the starting point is the margins. Normally the margins will be made up from WDK 102/WDK 103/WDK 100 or WDK 101. If you are using WDK 100 or WDK 101 for a margin always cut the tongue off fi rst, ensuring that you keep a straight edge. If the margin shape is intricate, a separate set of templates can be made.

Using WDK 106 (if the outside edge is not visible) or WDK 112 (if the outside edge is visible) draw the required shape directly onto the WDK 106 or WDK 112 (See Fig 11). Now mark where the inside edge is on WDK 106 or WDK 112 to identify the edge that requires ‘T’ Caulking (WDK 107).

(Fig 11)

Now cut out the shape with a sharp knife, fi rst score with the knife to start the cut (the blade of the knife should be at an angle of 80° towards the centre of the profi le, this will allow the ‘T’ Caulking (WDK 107) to sit fl ush with the profi le) and then cut deeper, it will take several cuts but the cut will be clean (See Fig 12).

(Fig 12)



When the shapes have been cut apply ‘T’ Caulking (WDK 107) to the inside edge only at this stage, making sure that the legs of the ‘T’ Caulking (WDK 107) are scored to allow the profi le to form to the shape without kinking (See Fig 13). It is advisable to allow an extra 20mm of ‘T’ Caulking (WDK 107) for fi nal trimming. Do not use the Stelmax (WDK X01) adhesive at this stage.

(Fig 13)

Once you are happy that the ‘T’ Caulking (WDK 107) will fi t fl ush to your shape without kinking, apply the Stelmax (WDK X01) adhesive to the leg of the ‘T’ Caulking (WDK 107) which will be adhered to the inside edge and glue in place (See Fig 14 & 15)

(Fig 14) (Fig 15)



Hold the ‘T’ Caulking (WDK 107) in place for 1-2 minutes to allow the adhesive to bond, making sure that there is a good bond between the ‘T’ Caulking (WDK 107) and profi le – no gaps. You can clamp the ‘T’ Caulking (WDK 107) in place if the radius of the bend is particularly tight (See Fig. 16)

(Fig 16)

Once the Stelmax (WDK X01) adhesive has set, hand sand using 40 grit sand paper, ensuring that you sand in the same direction as the plank. It is advisable to use a block when sanding, always sand away from the area you are sanding, this will prevent a build up of dust under the sanding block.

Once all the margins have been cut, ‘T’ Caulking (WDK 107) adhered to the inside edge and hand sanded, loosely place all the pieces in the appropriate places on the template. We are now ready to join the pieces together.

Choose your starting point, line the profi le up with the edge of the template where it needs to be fi tted

(See Fig 17 & 18)

(Fig 17)

(Fig 18)



Now join the pieces together using the ‘T’ Caulking (WDK 107) along the short edge of the profi le (See Fig 19 & 20)

(Fig 19) (Fig 20)

When joining the pieces together allow an extra 20mm of ‘T’ Caulking (WDK 107), this can be trimmed later (See Fig 20)

Once all pieces have been joined together and fi t the template correctly, they should be held in place on the template with double-sided tape or adhesive so they do not move when applying the infi ll (See Fig 21)

(Fig 21)



Mitred corners and hatch coversClear your working area and lay out your template ready (See Fig 22)

Page 15

(Fig 22)When making a mat to fi t a template the starting point is the margins. Normally the margins will be made up from WDK 102/WDK 103/WDK 100 or WDK 101. If you are using WDK 100 or WDK 101 as a margin always cut the tongue off fi rst, ensuring that you keep a straight edge.

For making mats with square mitred corners, fi rst cut profi les roughly to fi t template margins, decide on which corner to start. Lay one profi le over the other profi le on the corner at right angles (See Fig 23). (Fig 23)

Now fi nd the point at which the two profi les intersect and mark this point on the inside edge and on the outside edge of the profi le. Draw a line between these two points, now cut 2-3mm from this line making the profi le shorter, this will allow space for the ‘T’ Caulking (WDK 107).

When applying the ‘T’ Caulking (WDK 107) allow an extra 20mm in length and cut away the legs of the ‘T’ Caulking (WDK 107) on the outer edge (Fig 25) this will prevent the legs from protruding past the profi le/outer edge of the mat (See Fig 24 & 25)

(Fig 24)

(Fig 25)



(Fig 26)

Now adhere the ‘T’ Caulking (WDK 107) to the profi le, apply the Stelmax adhesive (WDK X01) to the legs of the ‘T’ Caulking and hold in place for 1-2 minutes until the adhesive sets, ensuring that there is a good bond between the profi le and the ‘T’ Caulking (WDK 107) – no gaps (See Fig 26).

Once the adhesive has set, trim the ‘T’ Caulking (WDK 107) to form a ‘V’ where the corner profi les meet.

Infi ll (Straight runs) Decide which way the planks are going to run. Now fi nd the centre point on the inside and outside edge (See Fig 27).

We are now ready to infi ll, using the WDK 100 fi nd the centre point of the brown area or the centre point of the black area (See Fig 28).

(Fig 27)

(Fig 28)



(Fig 29)

Deciding which centre point to use will depend on the size of the infi ll area, you need to determine which centre point will give you equal profi le widths to the outer edges. It is best to dry lay profi les to determine which centre point to use. Cut the profi les to the right length and once you are happy with the overall appearance of the planks you can start to bond them in place.

Starting with the middle piece, apply the Stelmax (WDK X01) adhesive to the edge that makes contact with the margin and hold in place for 1-2 minutes. Once the adhesive has set you can start to join the planks together, apply the Stelmax (WDK X01) adhesive to the ‘Tongue’ of your centre profi le and slot into the groove of the adjoining piece remembering to apply Stelmax (WDK X01) adhesive to the ends that make contact with the margin. Repeat this process until all the planks have been adhered (See Fig 29).

Once the mat has been completed and the Stelmax (WDK X01) adhesive has set, sand the mat using 40 grit sand paper ensuring that you sand in the same direction as the plank. It is advisable to use a block when sanding, always sand away from the area you are sanding, this will prevent a build up of dust under the sanding block. Sanding will remove any excess adhesive.

The mats are now ready for bonding to the deck.

Chapter 4 - Installing prefabricated mats


Installing your Dek-King Mats Laying your Dek-King mats with the adhesive provided is a relatively simple process. The following provides a step by step guide.

Surface Preparation - please it is important to remember that a lasting adhesion is dependent on the integrity of the surface beneath, e.g. if you have a painted deck make sure that paint lifting is not likely. A clean, dry and grease free surface is essential.

The adhesive supplied will allow some maneuverability when laying, however, it is advisable to dry lay the mats to ensure a good fi t and get a feel for how they will go down once the adhesive has been applied to the deck.

Take the mat up and prepare the surface for the adhesive. This entails a thorough clean of the area using a proprietary cleaner (and degreaser if required). It is OK to use acetone to clean the area, just be careful to keep it away from the Dek-King mats and only apply the adhesive once the area has dried properly.

Once the surface is clean, dry and grease free then you are ready to apply the adhesive. It is recommended that masking tape is used to catch the excess adhesive, and ensure the adhesive is applied to the edge of the mat area. Apply the adhesive over approximately 1 sq metre at a time.

The adhesive’s minimum working temperature is 5°C however 8-10°C is preferable. The maximum working temperature is 35°C

Using an applicator gun, apply to the area below the mat being careful not to use too much, more can be added later if required. Using a spreader, apply evenly over the entire area ensuring a good coverage and aiming for approx 3mm grooves at right angles to the run of the main plank area as this will ensure eff ective adhesion.

Chapter 4 - Installing prefabricated mats


Take hold of the mat and position the fi rst edge into place and slowly roll out over the adhesive, applying even pressure as you go. The unique ‘keyhole grooving system’ provides maximum contact between the mat and adhesive, so ensure that no air is trapped below the mat. If necessary it is possible to reposition the mat by sliding it smoothly as required. Once the mat is in the correct position, use the roller to apply strong, even pressure over the mat pushing out any build-up of adhesive and removing any trapped air. As a fi nal check for raised areas, run a hand over the mat feeling for any unevenness and rolling out these areas as required.

Check the positioning again and make any adjustments as required. Carefully clean away any excess adhesive that may be around the margin edge of the mat. White spirit is an eff ective cleaner for the Saba adhesive but is not recommended for use on the mat itself.

To ensure a clean and smart fi nish it may be necessary to run a line of adhesive around the edge of the mat if there is any gap between the material and the deck surface. It is also advisable around curved corners where a king plank has been used. This is best achieved by applying masking tape to the edge of the material and also to the deck and running a bead of adhesive into the gap. Smooth this off and leave to dry for 24 hours before removing the masking tape. Gently sand mat edges to restore the wood eff ect if required.

It is advisable to weigh down the mats with tubs or containers fi lled with sand or water and using wood planking to spread the weight as required over larger areas.

Note. Be careful if using water – although the adhesive is moisture curing it is best left for a couple of days before getting really wet.

The adhesive takes approx 24 hrs to cure at 24°C but this is dependent on operating conditions. A good rule of thumb is to leave for a minimum of 3 days before reinstalling any equipment and using your deck as normal. It should be OK to walk across as necessary but try to keep off as much as possible.

Date post:	20-Mar-2016
Category:	Documents
Upload:	robert-lindemann-kg
View:	223 times
Download:	3 times

Dek-King Installationsanleitung

Documents