Turnkey Solution for the Oil & Gas Sector Under the RAPID Project – Package 20A1

In large-scale oil and gas investments, rapidly deployable, durable, and high-capacity accommodation solutions that can be activated in parallel with the construction program are of critical importance. Within this scope, Dorce successfully delivered the 2,400-Person Integrated Workforce Accommodation Village for the Pengerang Integrated Petroleum Complex (PIPC) located in the state of Johor, Malaysia, under the RAPID (Refinery and Petrochemical Integrated Development) Project Package 20A1.

The project was executed under an EPC (Engineering, Procurement, and Construction) model for UEM Builders & Propel Consortium, with Petronas Refinery & Petrochemical Corporation Sdn. Bhd. as the project owner. All phases from design to commissioning were completed on a turnkey basis leveraging Dorce’s engineering expertise and modular construction capability in line with international standards.

Rapid Deployment and Industrial-Scale Modular Construction

The accommodation village was constructed on a total land area of 52,550 m² with 50,808 m² of enclosed building area, and was completed in only 12 months between December 2014 and December 2015. A Prefabricated Modular Steel Building System was used to fully comply with the demanding schedules of refinery and petrochemical investments.

Structural Systems and Technical Approach

A hybrid and high-strength structural methodology was applied. The project consisted of:

• 14 units of 4-storey Light Gauge Steel Frame (LGSF) modular steel buildings
• 36 units of 1 and 2-storey modular steel and pre-engineered steel buildings

This project is particularly significant as one of Dorce’s pioneering applications of 4-storey light gauge steel building systems.

All structures were designed in accordance with ASTM (American Society for Testing and Materials) standards, ensuring high structural performance against lateral loads, ocean-driven wind effects, and environmental conditions specific to the region.

Engineering Solution for Challenging Soil Conditions

Due to weak and problematic soil conditions in the Johor region, piled foundation systems were implemented, particularly for the 4-storey structures. This engineering approach ensured both structural safety and long-term performance reliability.

Turnkey EPC Scope of Services

Under the EPC model, Dorce delivered the complete project scope including:

• Architectural, structural, and engineering design
• Supply and manufacturing of modular steel buildings
• Electrical and mechanical (MEP) installations
• Transportation, customs clearance, and site logistics
• On-site assembly, testing, and commissioning

All processes were executed in full compliance with the stringent safety and quality standards of the oil and gas sector.

A Strong Reference for the Oil & Gas Industry

The 2,400-Person Integrated Workforce Accommodation Village under the RAPID Project represents a major reference demonstrating Dorce’s capability in delivering rapid-deployment, high-durability, and internationally compliant modular camp solutions for oil and gas developments. The project sets a benchmark particularly for refinery, petrochemical, and industrial investments across Southeast Asia and beyond.