By Bob Blochinger
Having worked on well over 100 yachts (from 50’ to 415’) during my years as a flooring contractor in Florida, I have experienced numerous challenges when installing flooring on yachts and marine vessels. The level of installation expertise is very high, not to mention the administrative processes.
Challenges include:
- There are no second chances. Repairs due to shoddy workmanship are not acceptable, ever.
- Higher rates are tolerated for an excellent level of workmanship, which is demanded.
- Damage to other areas of the vessel is not tolerated, such as scratching the walls, by any means from carpet backing or any tool and equipment usage.
- The vessel will adhere to its schedule. There is a small window of time for installation, and you are held to it.
- You may have to fabricate specific-use tools and equipment to successfully install both hard and soft flooring on marine vessels.
Over the years we fabricated specific use tools, equipment, and methods to successfully install both hard and soft flooring. As vertical extension planks for tackless, same strips used for Velcro method installation. Then there were the aluminum manufactured tackless available, from only one source.
Measuring is the first step, and it must be 100% accurate, detailed as to size required. Pre-cutting at the shop is another must, as you can’t just bring a 12’ roll on board and maneuver it into a cutting and fitting position. Some areas may require an edge trim, serging or binding. This project could be for a set of steps, access panels or an entire room with multiple access panels. (For example, a 50’ sport fishing boat will usually have two large panels for engine access in the salon.)
The carpet also needs to be easily removable for the customer to gain access as needed, then re-installed without damage, (as pulling up from pinned tackless and reinstalled). Basically, this requires a loose lay install that will not move, shift or buckle. Alternatively, a hard surface can be installed with a complementing edge trim, usually metal.
If the carpet is custom-made to fit or a production piece, paying careful attention to what you do is critical. Also that seam needs to be spot on and basically perfect.
Somehow since making holes in a deck of a boat is unreasonable, drilling or using screws, (tack strip), however each space for installation, has its own requirements, no two are alike.
This is where an adhesive is usually used. There are many kinds and types for specific installations, with positive results for the demanding conditions. Use of a Velcro system is also a solution. There are many types and sizes of materials used in these Velcro attachment systems.
The padding is also a consideration. Rubber, foam, re-bond and synthetic felt are typical types but not all are correct for marine use. Dense rubber is typically used for a laminated system (double stick), and synthetic felt with microbial resistance is also often suggested as it works well in a marine environment. Then there is foam pad with a thick vinyl layer, known as “sound down” since it’s used in rooms over the fuel tanks and to reduce engine noise.
This underlayment can be several inches in thickness and will require a height-extended tack strip. This is where we would cut plywood into strips as wide as three pin rows, and use the plywood’s thickness (or double it up) as needed. Also, make sure to install the pad with the foam side down and vinyl side up!
A best practice is to make a scaled diagram (cut plan), specify a pad that will work, then figure the height of the pad. Fabricate a paper template of the space so you can precut in the shop, especially if the carpet requires an edge trim, serge or bind.
Hard surface flooring requires the same attention to detail, whether installing sheet goods, LVT or a precut piece. Prepping the substrate is important, which in the case of a marine vessel might be wood, steel or fiberglass. Ensure the adhesive is rated for marine use.
Always use manufacturer-recommended products. You cannot second guess any step, procedure or product when installing on marine vessels. A private yacht is the owner’s pride and joy; you must respect this and perform accordingly.
