2,620-Person Prefabricated Modular Worker Accommodation Camp for the Aktogay Copper Mine Expansion Project Aktogay – Kazakhstan

The giant KazMinerals Aktogay Copper Mine Expansion Project in the Ayagoz region of Kazakhstan required uninterrupted operation under one of the world’s harshest climates, with severe winter conditions ranging between -40°C and -46°C. DORCE responded to this challenge with a 54,000 m² Prefabricated Modular Accommodation Camp for 2,620 People, executed with the EPC Contract model.

This project is not only a construction activity, but the peak of DORCE’s engineering and production power in the field of modular building solutions for harsh climates.

Volumetric Modular System: Speed and Quality Creating a Revolution in Construction

All critical living and social units of the camp were implemented with DORCE’s Registered Volumetric Modular Building System. This system provides unique efficiency for large scale site mobilizations requiring uninterrupted operation and maximum quality control.

Offsite Production: Logistics Revolution with Precision Flatpack Production in Türkiye

All units were produced in Türkiye in Flatpack Format, equipped with Climate Resistant Materials suitable for long distance shipment.
This Smart Flatpack Shipment strategy minimized international logistics costs and ensured precise control in the shipment schedule.

Almaty Assembly Facility: The Armoring Phase Against -46°C

The flatpack modules were transformed into three dimensional units at DORCE’s Special Volumetric Assembly Facility in Almaty.
Most of the electrical, mechanical and insulation systems were pre installed with High Quality Control in the Factory Environment, significantly reducing the working time in the extreme site climate.

Mega Logistics Achievement: The Frozen Route from Almaty to Aktogay

Transporting the volumetric modules across the hundreds of kilometers of freezing, icy route to the Aktogay site was considered the most challenging logistics step of the project.
DORCE completed this complex transportation operation smoothly and on time thanks to Special Security Protocols and Advanced Logistics Management.

Onsite Application: Final Assembly at Arctic Standards

On site, installation was carried out in accordance with Arctic Protocols by using heated assembly areas and anti freeze connection systems.
High Insulation Performance Panel Technology and Steel Systems with Special Wind and Snow Load Calculations guaranteed the safety and 40 Year Durability of the buildings.

The combination of Volumetric Modules made it possible to scale Large Volume Living Buildings at a speed unreachable by traditional construction.

The Prefabricated Living Area designed for the Aktogay Mine Project is an integrated living center that meets all social and daily needs of 2,620 workers:

Accommodation: Highly Insulated Modular Worker Dormitories and Executive Accommodation Units.

Social Facilities: Large Capacity Modular Dining Hall Facilities, Modular Social Facilities and rest rooms.

Luxury Feature: The camp’s large capacity Modern Laundry Facilities were installed inside Two Story Modular Buildings Equipped with Elevators. This special design enabled the laundry of thousands of workers to be transported quickly, ergonomically and uninterruptedly between floors, maximizing logistical efficiency and the physical comfort of the workers. This detail demonstrates the importance we place on flawless operational flow even under harsh conditions.

Support: Technical Maintenance Areas and HSE Management and Operation Offices were also integrated modularly into the complex.

This Sustainable Camp Construction provided uninterrupted operation and guaranteed safe and comfortable living areas for the workers of the KazMinerals Aktogay Project.