A 10,000-Person Integrated Modular Living City by DORCE for Africa’s Largest Energy Investment

The Mozambique LNG Project is recognized as one of Africa’s most strategic and high budget energy investments. In this major undertaking, DORCE continues to execute the design, production, shipping and on site installation of a large scale modular living city with a capacity of approximately 9,500 personnel, located only 1 km from the LNG site, in partnership with Renco and WBHO. This project is a benchmark example demonstrating how international standard modular construction technologies can be scaled under challenging geographic conditions.

Comprehensive Living, Social and Operational Facilities – Ongoing Installation Works

DORCE continues the installation of modular buildings covering all living and support units of the camp. Key units completed or currently under assembly within the complex include:

• Worker accommodation modules (each room with private WC and shower)
• Executive accommodation buildings and VIP living units
• High capacity dining halls
• Recreation and sports facilities
• Large scale laundry buildings
• HSE offices, medical clinic and fully equipped healthcare center
• Emergency response and security support units
• Technical rooms and operational facilities
• Warehousing structures supporting logistics flow

Each unit is produced using high durability prefabricated and modular steel systems designed to withstand the region’s tropical climate and cyclone risks.

Massive Modular Production Scope – 311 Buildings Completed for Shipment, Installation Underway

Two different shipment strategies were used within the project’s logistics model for the 311 buildings manufactured.

• All accommodation units were prepared in flat pack format and shipped to Africa in dismantled form.
• All social, administrative, operational and technical buildings were shipped as light steel structural components, panel systems, door window kits and MEP packages packed inside containers.

No building was shipped as a volumetric module. All structures are being assembled entirely on site.
This method maximizes logistics efficiency and demonstrates DORCE’s high capacity for large scale camp installations.

Despite the challenging geography and infrastructure limitations in Palma, Mozambique, DORCE successfully coordinated all logistics operations. Due to draft restrictions at the Port of Pemba preventing large vessels from docking, strategic planning was required.

Containers were transferred offshore or at intermediate points and brought to port using barge operations.
Despite all technical and physical challenges, DORCE’s integrated logistics solutions ensured safe, timely delivery of materials to site, maintaining alignment with the project schedule.

Heavy Steel Warehouse – The Industrial Backbone of the Project

One of the camp’s most strategic operational buildings is a heavy steel warehouse constructed by DORCE, considered one of the largest in the region.

Warehouse technical specifications:
• Height: 6,500 cm
• Length: 114,000 cm
• Width: 64,900 cm

Its large span heavy steel structural system provides a critical logistics management center supporting the entire camp’s operational workflow.

Integration of Modular, Light Steel and Heavy Steel Systems

Three different building systems are utilized harmoniously within the same complex:

• Modular container buildings: accommodation and operational units
• Light steel systems: social and administrative buildings
• Heavy steel systems: industrial service structures requiring high structural capacity

This combination provides maximum efficiency in durability, speed, functional diversity and sustainability.

Sustainability and Environmental Performance – Low Carbon Footprint

DORCE applies its Sustainable Camp Design approach to minimize environmental impact. All modular structures used in the project are equipped with:

• Energy efficient systems
• Water Saving Modular Systems
• Modern waste management infrastructure

DORCE’s Carbon Footprint and Water Footprint certificates document full compliance with international environmental standards throughout production and execution. These certifications demonstrate that all materials, production methods and logistics operations have been carried out in alignment with environmental sustainability criteria.

As a result, the Mozambique LNG camp stands as one of the region’s most sustainable large scale living complexes, with energy efficient modular buildings and minimized water and carbon consumption.

Site Works and HSE Management – Safety at International Standards

The installation phase is conducted with strict discipline, considering regional security challenges and climatic risks.

Actively implemented on site:

• HSE management procedures
• Occupational safety practices
• Emergency response planning
• Access control protocols
• Environmental risk mitigation measures

This comprehensive approach ensures that installation operations proceed safely, controlled and sustainably.