26,000-Person Mega Worker Living City Completed in Just 290 Days

Located in Abu Dhabi – Al Mafraq, one of the largest industrial clustering zones in the United Arab Emirates, the ultra-modern worker living city with a capacity of 26,000 people was delivered in record time by DORÇE Prefabricated & Construction under a turnkey EPC model. This mega-scale project was designed as an integrated and sustainable living city that meets all essential living needs of both blue-collar and white-collar personnel.

The employer of the project was Al Jaber Transport and General Contracting LLC, while the project owner was Zones Corporation. A 40-year Build–Operate–Transfer (BOT) model was adopted as the investment and operation framework. All design, engineering, manufacturing, and construction processes were carried out entirely under DORÇE’s engineering and production assurance.

From a 4-Year Construction Period to Just 290 Days

A project of this scale would normally require approximately four years to complete using conventional reinforced concrete construction methods. However, thanks to DORÇE’s industrial off-site manufacturing infrastructure, Light Gauge Steel (LGS) prefabricated systems, and fast modular assembly technologies, the project was completed in only 290 days.

This nearly 90 percent reduction in construction time enabled the employer to generate operational revenue three full years earlier, significantly increasing the financial efficiency of the BOT contract.

Structural Systems and Construction Technologies

The project implemented a hybrid structural approach, combining:

• Three-storey prefabricated modular buildings
• Light Gauge Steel (LGS) prefabricated systems
• Pre-engineered heavy steel structure systems

Through industrial-scale production and installation processes, a total of 14,392 tons of steel and 46,427 m³ of concrete were utilized, ensuring high structural durability, long-term usability, and operational continuity.

A Fully Equipped Modern Living City for 26,000 People

Spanning a total site area of 437,000 m² with 230,139 m² of enclosed built-up area, the complex offers a complete living ecosystem with full social and technical facilities. Within the scope of the project, the following were delivered in a fully integrated manner:

• Three-storey prefabricated modular and light steel worker dormitories
• Three-storey prefabricated modular accommodation buildings for engineers and technicians
• Executive residential units
• High-capacity dining halls, markets, and laundries
• Sports halls, indoor swimming pool, football and basketball fields
• Mosque, clinic, security units, and fire station
• Green areas, walking paths, and recreational zones

All processes, including electrical and mechanical works, finishing works, installation applications, and selected furniture supply, were managed by DORÇE on a turnkey basis.

EPC Strength and a Sustainable BOT Approach

The project was executed under an EPC model, covering engineering, manufacturing, logistics, transportation, and on-site assembly. It was structured in accordance with a BOT framework aligned with long-term operation and leasing objectives.

This approach created a safe, comfortable, and sustainable living infrastructure supporting industrial investments in the region.

A Globally Referenced Mega Camp Project

The 26,000-Person Mega Prefabricated Modular Worker Living City Project stands as a global reference demonstrating DORÇE’s leadership in delivering large-scale, fast-track, investment-driven living cities.

The project serves as a strong benchmark for similar mega camp and worker city developments across the Middle East, as well as in Africa and Asia.