General Contracting, Oil & Gas, Worker / Labor Accommodation Camps

A Turnkey Modular City in 12 Months for Russia’s Most Strategic Energy Investment

DORCE transformed the giant worker settlement project carried out within the scope of the AMUR Gas Processing Plant in the Svobodny – Amur Region of the Russian Federation, executed by Yamata Yatırım İnşaat Turizm ve Ticaret A.Ş. and Tecnimont S.p.A., into a global scale success by using Modern Methods of Construction (MMC). Under extreme winter conditions ranging between minus 40°C and minus 50°C, the installation of the prefabricated modular camp for 17,250 people was completed in only 12 months, and the project was recorded as one of the largest and fastest implemented worker settlements in the world. In this context, DORCE undertook the design, engineering and procurement processes and once again demonstrated its unique expertise in turnkey camp installation and international offsite production in harsh climates.

17,250 Person Integrated Worker City: Scope and Ambition

The project is an integrated Modular City that includes not only accommodation but also a fully equipped living, social and support campus. In the configuration, both Heavy Steel and Light Steel Systems were used together for maximum durability.

The Accommodation Areas include up to 3 storey Light Steel residential blocks, Worker Dormitories and Executive Apartments and Modular Living Units with High Insulation Performance. As Social and Community Facilities, 2 storey High Capacity Dining Halls, a fully equipped Health Center and Clinic, Modular Sports Halls, recreation areas, laundries and commercial units were constructed.

Among the Administrative and Support Buildings, 1 storey Security and Control buildings, Multi Purpose Administrative Offices and Storage and Logistics Support Areas were included as Training and Orientation Centers. In addition, including Water Treatment – Electricity – Sewer Infrastructure and Heavy Steel Industrial Facilities, all technical systems and internal roads were completed and a Fully Integrated Construction Site Infrastructure was provided.

Minus 50°C Engineering: Design Superiority for Arctic Climate

The engineering developed by DORCE for the Amur Gas Processing Plant was designed to eliminate Arctic Climate risks. In this design, Modular Steel Building solutions compatible with extreme Snow Load and Wind Load Calculations were applied. Thermal protection was provided with Special Thermal Insulation Packages and Anti Freeze Infrastructure Details. In addition, assembly planning suitable for darkness and Limited Working Hours and Safe Site Operations protocols in Extreme Climate Conditions were implemented.

12 Stage Accelerated Program: International Offsite Leadership

The on time and on budget delivery of the project is a direct result of DORCE’s global experience in international offsite production and site management. The project schedule was managed flawlessly in the stages of Fast Start (1 to 3 Months, Infrastructure and Ground), Main Configuration (4 to 6 Months, Accommodation and Social Areas), Heavy Integration (7 to 9 Months, Heavy Steel Facilities) and Final Delivery (10 to 12 Months, Testing and Commissioning).

Risk Management and International HSE Excellence

DORCE applied special risk protocols that fully comply with International HSE Procedures to ensure uninterrupted progress even at minus 50°C. With Reduction of Weather Related Delay Risks, Preventive Work Plans Against Freeze Related Assembly Interruptions and Workforce Rotation, operational continuity was ensured.

AMUR is the most striking proof of DORCE’s Modular Engineering Expertise, World Standard HSE Procedures and Global Leadership in Extreme Climates, backed by more than 40 Years of Experience.