A 16,000-Person Workforce Accommodation City Completed in Just 210 Days

Located in Al Mafraq, one of Abu Dhabi’s strategic industrial regions, the ultra-modern workforce accommodation city with a capacity of 16,000 residents was delivered at record speed under a turnkey EPC model by Dorce Prefabricated Building & Construction. The project was designed to provide safe, comfortable, and sustainable living infrastructure for both blue-collar and white-collar personnel working in major industrial and infrastructure investments.

The project client was Al Otaiba Enterprises, while the project owner was Zones Corporation. A 40-year Build-Operate-Transfer (BOT) model was adopted, and all design, engineering, manufacturing, and construction processes were executed entirely under Dorce’s integrated project management and production assurance.

Engineering Solutions Designed for Desert Climate Conditions

The Abu Dhabi and Al Mafraq region is characterized by extreme temperatures, high evaporation levels, and high energy demand. For this reason, the project was not only designed for speed but also optimized for climate-adaptive engineering solutions.

One of the key engineering highlights was the elevated water storage tower system, which enabled:

• Gravity-based water distribution
• Elimination of the need for continuous pump operation
• Reduced energy consumption and maintenance costs
• Increased long-term operational security

This solution created significant value in terms of operational efficiency and sustainability, particularly for large-scale residential camp developments.

Completed in 210 Days Instead of 4 Years

A conventional reinforced-concrete construction approach would have required approximately 4 years for a project of this scale. However, thanks to Dorce’s industrial off-site production capability, Light Gauge Steel prefabricated systems, and rapid modular assembly technologies, the accommodation city was completed in only 210 days.

This resulted in up to 90% time savings, enabling the investor to begin generating operational revenue three years earlier and significantly strengthening the financial return of the BOT model.

Structural Systems and Construction Technologies

A hybrid structural model was applied, combining the following systems:

• 3-storey prefabricated modular accommodation units
• Light Gauge Steel Frame prefabricated building systems
• 4-storey pre-engineered heavy steel buildings

A total of 6,779 tons of steel and 21,870 m³ of concrete were used throughout large-scale manufacturing and assembly operations, ensuring high structural durability, long-term performance, and operational continuity.

A Fully Equipped Modern Living City for 16,000 Residents

Situated on a land area of 109,349 m² and offering approximately 64,193 m² of enclosed building area, the accommodation city provides a complete living ecosystem with full social and technical infrastructure, including:

• High-comfort 3-storey prefabricated modular dormitories and executive lodges
• 4-storey steel-structured dining halls, industrial kitchens, and laundries
• Indoor sports halls and multi-purpose sports courts
• Mosque, clinic, security units, and fire station
• Large landscaped green areas, walking paths, and recreation centres

All disciplines — manufacturing, logistics, transportation, assembly, electrical and mechanical installations, and finishing works — were completed on a turnkey basis.

EPC Capability Combined with a Sustainable BOT Model

The project was delivered under an EPC model covering engineering, procurement, superstructure construction, and installation phases, and structured under a BOT operation model for long-term leasing and facility management goals. In doing so, a permanent, safe, and sustainable living infrastructure was created to support industrial investment activities in the region.

A Global-Scale Reference Project

The 16,000-Person Mega Prefabricated Modular Workforce Accommodation City Project once again demonstrates Dorce’s leadership in large-scale, high-capacity, fast-delivery accommodation cities. It stands as a powerful global reference for similar mega workforce camps and living city investments across the Middle East, Africa, and Asia.