Padel Court Material Quantities: The Complete Bill of Materials for One Court (2026)

By PeakPadel Engineering Team · Published September 2026 · 13 min read · Updated: 2026-09-01

1. Why Does Quantity Matter as Much as Quality?

The padel court buying conversation almost always starts with quality — steel grade, glass thickness, turf density — and that is correct, because the difference between a 5-year court and a 20-year court is decided by materials. But the conversation usually stops there, and that is where the trouble starts. Quantity is the second half of the equation, and it is the half that decides your freight bill, your customs declaration, your delivery schedule and your final budget.

Consider what happens when quantities are not nailed down. A buyer compares two "complete kit" quotes and picks the cheaper one, only to discover at delivery that doors and anchor bolts were excluded, that the glass area is 30 m² short of a fully glazed back wall, or that the sand infill was never in the kit at all. Freight is quoted on the wrong tonnage, customs is undervalued or overvalued, and the installation crew arrives to find bolts missing. Every one of these is a quantity problem, not a quality problem — and every one of them is preventable with a single page of numbers.

The quantities below are for one standard outdoor court at the official FIP playing size of 20 x 10 m. They come from the same factory documents used for our own production planning and container loading, so they are working numbers, not marketing figures. Panel counts vary with panel width and corner details, and panoramic designs sit at the top of every range — but a buyer who understands the baseline will see exactly where a quote drifts from it.

2. What Is the Complete Quantity Table for One 20 x 10 m Court?

Read the table the way a factory does: it is a loading list. Every row is something that has to be fabricated, checked, crated and loaded, and every row that is missing from a competitor's quote is a row you will pay for later on site. The sections below explain where the numbers come from and where they flex.

3. What Is the Steel Structure of the ~4-Tonne Skeleton?

The steel structure is the heaviest single line in the kit — roughly 3.5-4.5 tonnes of Q235B structural steel per court, hot-dip galvanized to protect against rust for the life of the court. It breaks down into the columns that carry the glass and mesh (about 20-24 posts around the perimeter in a classic post-and-panel layout, fewer in panoramic designs), the perimeter beams and rails that tie them together, and the base plates and gussets that transfer every load to the foundation. A full court, including glass, turf and sand, lands around 13 tonnes of dead load — the figure your site's structural engineer needs when the court goes on a roof deck or a suspended slab.

Two quantity questions separate serious suppliers from assemblers. First, galvanizing weight is part of the tonnage — a court with hot-dip galvanizing (≥ 70 µm) carries more metal than one that is merely painted, and the difference shows up in the freight bill as well as the rust warranty. Second, the foundation anchors are in the kit: anchor bolts cast into the ring beam, plus SUS304 stainless bolts, nuts and washers for the whole structure. Stainless hardware costs more per kilo than carbon steel and is the single most common item quietly excluded from "complete kit" pricing. Ask for the steel BOM line by line — columns, beams, base plates, gussets, anchor bolts, hardware — and compare like for like.

4. How Much Tempered Safety Glass Is Needed at 190-210 m²?

Glass is where quantity and quality are easiest to confuse, because the area changes with the design. A standard court uses 40-46 tempered glass panels totalling about 190-210 m², including doors. The layout is systematic: back walls (10 m each end) are fully glazed with 2 m x 3 m panels — five per end — plus 1-2 glass doors; side walls use a 2 m panel module at the standard height, with the count depending on whether the design is classic (glass below, mesh above) or fully glazed. Panoramic courts push the total to the top of the range; the exact panel count also moves with panel width, because some factories use 2.5 m panels to cut the number of joints.

The weight is as important as the area. 12 mm tempered glass weighs about 30 kg/m², so a single 2 m x 3 m back-wall panel is roughly 180 kg — which tells you why installation needs a crane or lifting crew, and why the crating plan matters. Two checks protect you: confirm the glass is 12 mm tempered to EN 12150 (10 mm is sometimes substituted on budget quotes for indoor courts, where wind load is lower), and confirm the count in the quote matches the wall layout in the drawings. The difference between 40 and 46 panels is not just area — it is joints, gaskets, crating and crane time.

5. What Is the Turf & Sand 200 m² Surface System?

The playing surface is a two-part system, and it is the part buyers most often under-quantify. The turf order is ~230 m² for a 200 m² court — the extra 30 m² covers overlaps at the seams and the cuts around posts and doors. Standard padel turf is a 24 mm monofilament carpet at 10,000-13,000 stitches per m², chosen for the controlled slide that padel demands and the UV resistance that outdoor play requires.

The second half is the silica sand: 14-20 kg/m², which works out to 3-4 tonnes per court. The sand is oven-dried and rounded (0.2-0.8 mm) so it packs without cutting the fibres, and it is filled to 60-70% of the pile height — deep enough for a controlled slide, shallow enough to keep the court fast. Two practical notes: sand is heavy, so it is often sourced locally to save freight (factory-supplied sand is an option on most orders), and the same 14-20 kg/m² figure is what you will need again in year 3-5, when play has migrated the infill and the court is topped up. For the full maintenance picture, see our maintenance guide.

6. What Mesh, Net, Doors & Hardware Are Needed?

Around and above the glass, the enclosure is finished in galvanized or powder-coated metal mesh — a 50 x 50 mm grid of about 3 mm wire that contains the ball without blocking light or view. The 1 m band above the glass runs the full 60 m perimeter, roughly 60 m², and classic layouts add mesh above the lower glass on the side walls. Mesh is also where the "complete kit" game is played: some quotes price the glass and steel and quietly leave the mesh, doors, net and fittings as "extras" discovered at installation.

The smaller lines matter more than their price suggests. The net is one set per court — 10 m wide, 0.88 m at centre and 0.92 m at the posts — and it is cheap to make but awkward to source locally with the right tensioning. The 1-2 doors (a glass access door plus an optional maintenance gate) are factory-fitted into the panel layout, so they cannot be added later without re-cutting glass. And the hardware — SUS304 stainless bolts, nuts, washers, anchor bolts and the neoprene gaskets at every glass-to-steel contact — is the difference between a court that stays tight for a decade and one that rattles loose in a season. A line-by-line BOM makes these visible before you sign, not after.

7. What Lighting & Electrical Components Are Required?

Lighting is specified by lux, not by count, but for quantity planning the working figure is 4-6 LED floodlights per court on galvanized poles: 200 lux covers recreational play, 300-500 lux covers club and regional competition, and national or broadcast events step up to 750 lux and beyond. The quantity flexes with pole placement (two poles per side is the common pattern) and with the choice between standard and glare-controlled optics — the latter matters wherever courts sit near housing. Lighting is usually quoted as an option line rather than part of the base kit, so confirm whether the quote includes poles, cabling and mounting hardware or only the fixtures. For the technical detail, see our lighting guide.

8. How Do Weight, Containers & Freight Math Work?

Quantities become logistics the moment the order is confirmed, and the arithmetic is simple if the BOM is real. A complete single-court kit — steel, glass, turf and hardware — fits in one 40 ft container in the standard classic configuration; a double-court order needs two containers, and panoramic glass designs need extra care in crating because the panels are larger. The full delivered weight of about 13 tonnes per court is the number your freight forwarder quotes on, and the number on your customs declaration, so an understated BOM produces an understated invoice and a customs problem at the port.

Three logistics decisions belong in the BOM discussion, not after it. First, decide whether sand ships with the kit or is sourced locally — it is 3-4 tonnes of the 13, and freight on sand is rarely worth paying across an ocean. Second, confirm crating is included: glass in steel-framed crates, steel structure wrapped against corrosion, hardware boxed and labelled per panel. Third, get the per-container packing list from the factory so the crew on site knows which crate holds the bolts. The full process — container loading, freight times, customs and insurance — is covered in our shipping guide.

9. How Do You Compare Factory Quotes Against This BOM?

A factory quote is only comparable when every line is visible. Before you compare two suppliers, turn both quotes into the same table — component, quantity, specification, unit price — and check these eight points:

1. Steel tonnage and finish: how many tonnes, and is it hot-dip galvanized (≥ 70 µm) or painted?
2. Glass area and thickness: how many m² and panels, at 12 mm EN 12150?
3. Mesh: is the top band and side sections included, in the quantity the wall layout requires?
4. Turf: is the order for 230 m² (with overlaps) or a bare 200 m² that will fall short at the seams?
5. Sand: is infill included, at 14-20 kg/m², or quoted separately or excluded?
6. Doors and hardware: are the 1-2 doors, SUS304 fittings, anchor bolts and gaskets in the kit?
7. Lighting: fixtures only, or poles, cabling and mounting hardware?
8. Documentation: CE marking, ISO 9001, material certificates and the BOM itself — a factory that publishes its own quantity list has nothing to hide.

Where a quote differs from the table, ask for the reason before assuming it is a saving — fewer panels may mean wider panels (fine, if the drawings confirm), but fewer kilograms of steel usually means less steel. Quality and quantities together decide what your court really costs over its life: the quality guide explains which materials to specify, this BOM tells you how much of them to expect, and the 2026 cost guide turns both into a budget.