Flat-Packs for the Copper Belt: 9States' 500-Bed Mining Camp in the DRC, Delivered Through 2,500 km of African Logistics

Project Background

The Democratic Republic of the Congo (DRC) is the world's largest cobalt producer and one of Africa's leading copper producers. Its Copper-Cobalt Belt, spanning the provinces of Haut-Katanga and Lualaba, is one of the richest copper-cobalt mining districts on Earth. From 2025 to 2026, as global demand for copper and cobalt surged driven by the clean energy transition, multiple international mining giants have been expanding capacity across the DRC.

This region is home to numerous large-scale mines — from the Tenke mining area to the Congo mining corridor, both open-pit and underground operations running simultaneously across dozens of sites. Most mines are located in the vast area between Lubumbashi and Kolwezi, far from towns and cities. Mine expansion requires a significant increase in the workforce, yet existing worker accommodation facilities are severely inadequate. Many workers are forced to commute daily from towns tens of kilometers away.

An international mining group operating in Lualaba Province contacted 9States to deliver a standardized 500-bed worker camp for its copper-cobalt mine expansion project.

Project Requirements

Challenges with Conventional Construction

Using traditional brick-and-mortar construction in remote DRC mining areas presents formidable obstacles:

• Local building material supply chains rely heavily on imports, with cement and steel prices remaining high and supply unreliable
• During the 6-month rainy season, there are approximately 20 rainy days per month, leaving extremely limited windows for concrete pouring and curing
• Remote areas lack skilled construction workers and technical personnel
• Material transportation distances are extreme — approximately 2,500 km by road from Dar es Salaam Port to the Lualaba mine site, with numerous checkpoints along the way, making both cost and delivery timelines difficult to control

9States' Solution — Flat-Pack Modular Camp

9States delivered a 500-bed flat-pack modular camp solution, specifically customized for the DRC's highland tropical savanna climate and Africa's inland logistics challenges.

Camp Layout

The camp is divided into three functional zones: Accommodation Zone — 130 modular dormitories (4 persons each) with private bathrooms and split-type air conditioning; Public Services Zone — a 200-seat mess hall, medical clinic, laundry, and recreation room; Administration Zone — 10 offices and 2 meeting rooms. All buildings are arranged in a herringbone layout to save space and facilitate phased expansion.

Climate-Adapted Design

• Raised steel chassis: Modules elevated 30 cm above ground to prevent rainwater ingress and termite infestation
• Enhanced corrosion protection: Wall panels using Galvalume steel with polyurethane sandwich panels (corrosion class C3+) to withstand the alternating humid and dry conditions of the highland rainy season
• Split-type air conditioning: Inverter units in all dormitories for temperatures up to 34°C
• Extended eaves: 1.2-meter eaves on all buildings reduce direct sun exposure and rain splash on walls during the wet season
• Rainwater harvesting: Roof drainage systems and storage tanks capture wet-season rainfall for dry-season cleaning use
• Solar-ready design: Roof structure pre-engineered for future photovoltaic panel installation, allowing the mine to add solar capacity later to reduce operating costs

Supply Chain & Logistics

Each module is factory-produced in 9States' Shanghai plant in flat-pack form, folding to approximately 30 cm thick panels that fit into standard 40-foot shipping containers. The journey: Shanghai port → Malacca Strait → Indian Ocean → Dar es Salaam Port — approximately 10,500 km, transit time about 22 days.

After customs clearance, containers travel approximately 2,500 km by road via the Zambia–DRC corridor to the Lualaba mine site. Cargo is dispatched in batches of 8–10 containers per week, synchronized with on-site foundation work. On arrival, a 4-person team can assemble each flat-pack module in approximately 30 minutes using only hand tools — no welding or heavy lifting equipment required.

Project Specifications

Client Feedback

"Building worker accommodation in remote DRC mine sites has always been a major challenge. 9States' flat-pack solution solved many practical problems — everything arrives at site in a single container, no need to source building materials locally, and installation continues without delay even during the rainy season. Our workers are very satisfied with the living conditions — the inverter air conditioning ensures comfort in the highland climate." — Project Operations Manager

Why 9States for African Mining Camp Projects?

• Flat-pack design: 50% freight savings, manual tool assembly on-site
• Highland tropical climate adaptation: Raised steel chassis for moisture and termite protection, Galvalume C3+ corrosion protection, extended eaves, and rainwater harvesting systems
• Standardized system: 180 modules flexibly configurable and easily expandable
• Rapid deployment: First occupancy within 12 weeks from order placement
• Inland Africa logistics expertise: Complete supply chain solution from Dar es Salaam Port to remote mine sites
• Relocatable: Camp can be dismantled and moved to new sites; over 90% reusability rate
• 15-year design life suitable for the DRC's highland environment

For more information about mining camp solutions in Africa, visit 9States at 9prefabhouse.com.