1,200 Workers, 50°C, 6 Weeks: 9States Delivers a Desert-Proof Camp for Saudi Arabia's Phosphate 3 Project

Project Background

By early 2025, Saudi Arabia's mining sector had entered a rapid expansion phase. Ma'aden — the Saudi Arabian Mining Company — officially commenced construction on its Phosphate 3 project in Wa'ad Al Shamal, a SAR 28 billion (approx. USD 7.4 billion) investment aimed at boosting national phosphate production capacity to 9 million tonnes per year.

With the construction workforce expected to peak at several thousand workers on site, the project owners needed a fast-deployable, high-capacity worker camp that could withstand the extreme desert conditions of the Northern Borders Province — where summer temperatures regularly exceed 50°C (122°F), sandstorms are frequent, and the site sits over 400 km inland from the nearest industrial port at Ras Al Khair.

9States was engaged to design, manufacture, and deliver a modular worker accommodation camp capable of housing 1,200 workers across a single-phase deployment, with full provisions for dining, recreation, medical services, and site management offices.

Environmental Challenges

The project site presented several severe environmental constraints:

• Extreme heat: Summer air temperatures consistently exceed 48°C, with surface temperatures reaching 70°C on exposed steel surfaces
• Sand and dust ingress: Frequent shamal winds carry fine sand particles that can penetrate standard building seals within weeks
• Intense UV radiation: Year-round direct sunlight accelerates degradation of exterior coatings and interior materials
• Remote logistics: Containers shipped via Ras Al Khair Port must travel approximately 440 km inland by road to reach the northern border site
• Limited on-site water and power: The camp must operate as a largely self-sufficient facility with integrated generator backup and water storage

9States Solution: Desert-Adapted Modular Units

1. Heat & Sand Seal Protection

Every unit was manufactured with double the standard sealant application at all panel joints, window frames, and cable penetration points. High-temperature silicone sealant (rated to 150°C) was used throughout. Door and window openings were fitted with thermal-break aluminum frames and double-glazed Low-E glass to minimize solar heat gain while maintaining a clean sand seal.

External sand-deflection channels were integrated into the roof-to-wall junction to guide windblown sand away from critical seals, extending the service life of gaskets and weather stripping.

2. Enhanced Electrical System

To support 24-hour air conditioning loads, the electrical system was designed with 35% additional power capacity over standard specifications. All wiring uses 105°C-rated flame-retardant copper conductors with one gauge size upgrade throughout. Each accommodation block is equipped with thermal-protection distribution boards and ventilated junction boxes to prevent overheating failures in peak summer.

3. UV & Corrosion Protection

The exterior cladding was treated with UV-resistant anti-corrosion coating, while interior surfaces — including wall panels and flooring — were specified in modified PVC and flame-retardant ABS sheet materials that resist heat-induced yellowing.

Roof units are fitted with shading canopies elevated 30 cm above the roof surface, creating an air gap that reduces direct solar gain on the main roof panel by an estimated 35%.

Camp Layout & Configuration

Total Workers Accommodated: 1,200
Accommodation Units: 300 units (4 workers per unit, en-suite bathroom)
Common Facilities: Central mess hall (350 seats), recreation hall, laundry, medical clinic, mosque
Office Modules: 24 site management office units with meeting rooms & IT server room
Total Site Area: Approx. 18,000 m²
Containerized Units Supplied: 420 units (6m × 3m flat-pack)
Design Life: 15 years under desert conditions
Construction Period (On-site): 6 weeks

Logistics & Delivery

The units were manufactured at 9States' production facility in Shanghai and shipped to Ras Al Khair Port via the Arabian Gulf. Total shipping volume: 78 × 40-ft containers. From Ras Al Khair, units were trucked approximately 440 km northwest to the Wa'ad Al Shamal construction site, with delivery phased over 3 weeks.

Client Feedback

"The desert-adapted design of these units made a real difference. Even during the peak of last July, when outside temperatures hit 52°C, the internal temperature of the accommodation modules remained below 30°C without overloading the AC units. We saw zero seal failures through the first summer season."

— Project Camp Manager, Engineering & Construction Division

"Delivery was on time, assembly went smoothly, and the workers appreciated having proper en-suite bathrooms and cool sleeping quarters in the middle of the desert."

— Logistics Coordinator, Site Development Team

Why 9States for Your Middle East Camp Project?

With extensive experience across GCC countries, 9States delivers desert-adapted modular solutions including:

• High-temperature sealant application at 1.5× standard density
• Thermal-break aluminum doors & windows with Low-E double glazing
• 105°C-rated electrical system with 35% power headroom
• UV-resistant exterior coating with sand-deflection design
• Flat-pack design for cost-effective shipping and rapid on-site assembly

Contact 9States today to discuss your project requirements. We deliver tailored modular solutions built for your environment.