How We Build Courts — And Why the Details Matter

How We Build Courts — And Why the Details Matter

Building a high-quality pickleball, tennis, or basketball court is not just about the surface you see — it’s about the decisions made long before the first coat is applied. This guide outlines the construction standards, sequencing, and technical considerations we follow on every project to ensure consistent performance, durability, and long-term value.

This is not a DIY manual. It’s an inside look at the professional process behind a properly built court.

At SPC OP, LLC, we’ve seen firsthand how small shortcuts during grading, drainage, concrete preparation, and surfacing can quietly reduce a court’s lifespan and play quality. Many of these issues don’t show up immediately — they appear months or years later as cracking, pooling water, surface failure, or inconsistent play.

This guide exists to explain what goes into doing it right — and why experienced planning and execution matter.

Whether you’re a homeowner, school, HOA, or commercial facility, understanding the construction process helps you ask better questions, evaluate proposals more clearly, and avoid costly mistakes. Our goal is transparency — so you know exactly what you’re investing in when you hire a professional court builder.

If you’re considering a new court or resurfacing project, we’re happy to walk you through these steps and how they apply to your site.

→ Get a Free Court Quote

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1. Initial Site Evaluation

Every successful court begins with an honest evaluation of the site. Conditions that appear acceptable for general concrete work may create long-term problems for athletic surfaces.

Key considerations include:

• Site access: Space for excavation, concrete placement, and finishing equipment
• Grading and elevation: Ability to achieve proper slope without excessive fill or retaining structures
• Drainage behavior: How water enters, moves across, and exits the site during heavy rainfall
• Surrounding features: Adjacent hardscape, landscaping, roofs, and structures that influence water flow

Courts fail more often from unmanaged water than from surface materials. Drainage must be evaluated early, not assumed.

2. Site Preparation & Excavation

Proper site preparation establishes the conditions the slab will live with for decades.

• Clearing and grading: All organic material, roots, and debris must be removed. Tree roots left in place frequently lead to settlement and cracking later.
• Subgrade compaction: Compaction to approximately 95% Standard Proctor density is commonly required, but moisture conditions and soil type are equally important.
• Aggregate base: Typically 4–6 inches of compacted crushed stone to provide stability and drainage.
• Cushion sand (if used): A thin leveling layer to assist with final grade adjustments.
• Moisture barrier: A continuous polyethylene vapor barrier (commonly 12 mil) to limit moisture migration into the slab.

These layers function as a system. Shortcuts taken here are difficult—or impossible—to correct later.

3. Concrete Slab Systems & Reinforcement

Concrete for courts must be selected and detailed with surface performance in mind, not just structural adequacy.

Common systems include:

• Reinforced concrete slabs: Typically using #3 rebar at minimum 18-inch spacing. Crack control depends heavily on site conditions and execution.
• Post-tensioned slabs: Use tensioned steel cables to reduce crack concentration and are often preferred for high-performance courts.

Control joints, when used, must be planned carefully. While joints are common in general concrete construction, they often conflict with acrylic-coated athletic surfaces.

4. Concrete Mix Design & Placement

Typical performance-oriented mix characteristics include:

• Minimum 4000 PSI compressive strength
• 5–7% air entrainment in freeze–thaw climates
• Controlled water-to-cement ratio to limit shrinkage
• Properly graded aggregates

Courts are commonly poured 4–6 inches thick, with 5" min slabs used for post-tension systems or poor soil conditions.

Slope is critical. Courts are generally constructed with approximately 1 inch of fall per 10 feet to promote surface drainage without affecting play.

5. Surface Finishing & Tolerances

Surface finish directly affects both playability and coating performance. Courts require tighter tolerances than typical concrete work, and surface texture must be compatible with acrylic coating systems.

• Flatness & Leveling:
  Surface deviations should not exceed 1/8 inch over 10 feet.
• Low and High Spot Management:
  Irregularities must be corrected prior to curing to avoid future grinding or patching.
• Concrete Surface Profile (CSP):
  A properly executed medium broom finish is appropriate and preferred for sport courts and typically produces a surface profile consistent with CSP 3–4, which aligns with acrylic coating manufacturer bonding requirements.

6. Surface Preparation for Acrylic Coatings

Acrylic coating performance depends on the actual surface profile achieved, not solely on how the surface was finished.

• Curing:
  New concrete must cure for a minimum of 28 days prior to coating.
• Surface Profile Verification:
  Acrylic manufacturers typically require a Concrete Surface Profile of CSP 3–4 to ensure proper bonding.
• Mechanical Surface Preparation:
  Grinding or shot blasting is required if a CSP 3–4 surface profile was not achieved during the concrete finishing process, or if curing, laitance, or surface sealing has reduced effective surface texture.

7. Acrylic Coating Systems

Established acrylic sport court systems are designed as layered assemblies and should be applied according to manufacturer guidance.

Commonly used systems include those produced by SportMaster, Acrytech, Laykold, and Plexipave. Performance depends more on surface conditions and preparation than on brand selection alone.

Courts Are Not Driveways

One of the most common causes of court failure is treating court construction like standard concrete work. Driveways and parking lots are designed to carry load. Courts are designed to deliver consistent playability.

Using conventional concrete practices without adjustment often leads to:

• Ponding water
• Crack telegraphing
• Coating adhesion failure
• Premature resurfacing cycles

A court is a performance surface, not decorative concrete.

Final Notes

This overview is intended for educational purposes and reflects commonly accepted industry guidance, including principles established by organizations such as the U.S. Tennis Court Builders Association. It does not replace engineered plans, professional judgment, or site-specific evaluation.

Well-built courts result from understanding how standards interact with real-world conditions, not from treating construction as a checklist.

For those seeking deeper insight into why courts fail—even when built “to standard”—and how risk accumulates through sequencing, assumptions, and execution, more detailed guidance is available beyond this introductory overview.