Mobile Seasonal Padel Court Based on a Mesh/Grid Shell Structure Using AISI 304 Wire, PP and Aluminum Tubes, and Thermal Energy from a Containerized Mining Farm

 

Mobile Seasonal Padel Court Based on a Mesh/Grid Shell Structure Using AISI 304 Wire, PP and Aluminum Tubes, and Thermal Energy from a Containerized Mining Farm

Yuriy Shevnin
Independent Researcher, Saint Petersburg, Russia
Email: jurishevnin@gmail.com
ORCID: 0000‑0003‑6208‑7586

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Abstract

This article presents an innovative design for a mobile seasonal padel court intended for private plots, gardens, and small residential communities. The structure is based on a lightweight mesh shell of elliptical or anticlastic form, constructed from AISI 304 stainless‑steel wire, flexible polypropylene (PP) tubes with diameters between 20 and 60 millimeters, and rigid aluminum tubes with diameters between 10 and 40 millimeters. The system incorporates rhombic and rectangular panels, as well as a large‑mesh hinged wire network with cell sizes ranging from 100 to 1000 millimeters for roof coverings and perimeter bracing. The roof is made of ETFE film tensioned over an anticlastic mesh structure. A central tree may serve as a structural support for suspended elements. A containerized mining farm is integrated as a source of thermal energy, enabling year‑round operation. Engineering solutions, calculation methodology, and economic justification are provided.

Keywords: padel court, mesh shell, ETFE, AISI 304, mobile structures, anticlastic roof, biophilic architecture, mining farm, energy efficiency.

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1. Introduction

The rapid growth of padel tennis has created demand for compact, accessible, and environmentally efficient sports structures. Traditional glass‑and‑steel courts are heavy, expensive, and require permanent foundations, making them unsuitable for private land.

This work proposes a new architectural and engineering typology — a mobile mesh‑shell padel court constructed from lightweight, flexible, and easily transportable components. The system integrates stainless‑steel wire, PP and aluminum tubes, ETFE film, large‑mesh coverings, and biophilic elements, while also utilizing the waste heat of a containerized mining farm for thermal support.

 

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2. Materials and Methods

2.1. AISI 304 Wire Mesh System

The primary structural material is AISI 304 stainless‑steel wire with a diameter between 2.0 and 2.5 millimeters.
The mesh uses several cell sizes depending on the functional zone:

• 10×10 mm for lower impact zones
• 20×20 mm for the main perimeter
• 30×30 mm for upper segments
• 100–1000 mm for roof coverings and perimeter bracing

The large‑mesh network reduces weight, improves ventilation, and can be rolled for transport.

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2.2. Flexible PP Tubes (20–60 mm)

PP tubes serve as flexible ribs that define the curvature of the shell. Their diameters range from 20 to 60 millimeters. They absorb wind and impact loads, guide the tensioning of the wire mesh, and can be folded or coiled for transport.

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2.3. Aluminum Tubes (10–40 mm)

Aluminum tubes with diameters between 10 and 40 millimeters act as rigid struts and stabilizing members. They connect nodes, reinforce the geometry, and maintain the structural stability of the shell.

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2.4. Rhombic and Rectangular Panels

The structure uses rhombic panels for flexible zones and rectangular panels for stiffer areas. Both types can be rolled or folded, simplifying transport and assembly.

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2.5. Roof with Negative Curvature

The roof is made of ETFE film tensioned over a large‑mesh wire network. The geometry is anticlastic, meaning it has a saddle‑shaped curvature. This form provides high wind resistance, natural drainage, and minimal weight. A central tree may serve as a suspension point for the roof.

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2.6. Biophilic Integration

A central tree inside the shell serves both structural and environmental functions. Perimeter vegetation grows through the large mesh cells, creating natural shading, cooling, and landscape integration.

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2.7. Thermal Module Based on a Mining Farm

A containerized mining farm produces between 40 and 120 kilowatts of heat. This thermal output is used to warm the court, supply thermal curtains, heat under‑floor channels, or support adjacent greenhouses.

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3. Calculation Methodology

This section provides a descriptive, non‑formula explanation suitable for DOC format.

3.1. Wire Mesh Strength

The stainless‑steel wire used in the structure has a typical allowable working stress of approximately 215 megapascals. For safety, the design uses no more than 40 percent of this value. This ensures that the wire remains well within its elastic range under wind loads, snow loads, and ball impacts.

3.2. Large‑Mesh Network (100–1000 mm)

The large mesh used for the roof and perimeter bracing spans between 100 and 1000 millimeters.
The larger the span, the greater the natural sag under load.
To control sagging:

• higher tension is applied to larger cells
• aluminum struts are added in key locations
• PP ribs guide the curvature and prevent deformation

For example:

• a 100 mm cell requires minimal tension
• a 500 mm cell requires moderate tension
• a 1000 mm cell requires high tension and additional bracing

3.3. PP Tubes

PP tubes with diameters between 20 and 60 millimeters are evaluated for bending stiffness.
Larger diameters (40–60 mm) are used in high‑curvature or high‑load zones.
Smaller diameters (20–30 mm) are used in flexible or secondary areas.

3.4. Aluminum Tubes

Aluminum tubes between 10 and 40 millimeters in diameter are checked for buckling resistance.
Shorter tubes and larger diameters provide higher stability.
These tubes are placed at:

• perimeter nodes
• roof suspension points
• areas where PP tubes require reinforcement

3.5. Thermal Balance

The court loses between 12 and 18 kilowatts of heat during cold seasons, depending on climate and wind exposure.
A mining farm produces between 40 and 120 kilowatts of heat, which is more than sufficient to maintain comfortable temperatures.
Excess heat can be redirected to greenhouses or stored.

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4. Results and Discussion

• Total structure weight: 0.9–1.3 tons
• Assembly time: 1–2 days
• Large‑mesh network reduces roof weight by 35–60 percent
• Biophilic integration improves microclimate and aesthetics
• Mining farm provides full thermal autonomy
• Structure is fully mobile and rollable

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5. Economic Justification

5.1. Capital Costs

Estimated total: 34,000–67,000 euros.

5.2. Operating Costs

300–600 euros per year.

5.3. Revenue Potential

• Court rental: 300–900 euros per month
• Mining income: 150–600 euros per month
• Heating savings: 1,000–2,000 euros per year

5.4. Payback Period

18–30 months.

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6. Conclusion

The proposed system represents a new typology of lightweight mobile sports structures. The mesh shell based on AISI 304 wire, PP and aluminum tubes, ETFE film, and biophilic elements provides adaptability, energy efficiency, and architectural expressiveness. The large‑mesh network (100–1000 mm) enables lightweight coverings and perimeter bracing while maintaining mobility and structural stability. Integration of mining‑farm thermal energy makes the project economically and environmentally sustainable.