heavy - large breeds require 10 square feet per bird
Bantam - smaller breeds require around 6-8 square feet per bird
as for materials don't know whats in your area but most build it out of 2X4s and a strong welded metal fencing with close spacing.
As for keeping predators out, know your predators in your area, RESEARCH them to learn their habits.
Example in my area the only true predators are dogs and skunks, so I have a secure building for them to sleep in at night, a guard dog for the day time, a chain-link fence surrounding the whole backyard and a security camera that I can watch from inside the house. Since I'm a stay-at-home mom, I feel this is enough for me.
If you have a lot of predators, then you want to make sure you build a "mote" around your run with buried fencing to discourage digging under it. Make sure there are no gaps or weak spots in the fencing either.
I've read about a lot of people here that had the smallest opening and thought nothing of it, just to find out how quickly a raccoon can open it up. Someone even posted a video of a fox actually climbing their run fencing to get in at a weak point on top.
Some use electric fencing to help ward off predators, especially larger ones like coyotes and such.
If you look at the coops shown on here, you can get a good idea of how others have done their runs.