By early 2025, Saudi Arabia's mining sector had entered a rapid expansion phase. Ma'aden 鈥?the Saudi Arabian Mining Company 鈥?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 鈥?where summer temperatures regularly exceed 50掳C (122掳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.
The project site presented several severe environmental constraints:
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掳C) was used throughout. Door and window openings were fitted with thermal-break aluminum frames (bridging 鏂ˉ閾?profile) 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.
To support 24-hour air conditioning loads, the electrical system was designed with 35% additional power capacity over standard specifications. All wiring uses 105掳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.
The exterior cladding was treated with UV-resistant anti-corrosion coating, while interior surfaces 鈥?including wall panels and flooring 鈥?were specified in modified PVC and flame-retardant ABS sheet materials that resist heat-induced yellowing and maintain dimensional stability at high temperatures.
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%.
| Item | Details |
|---|---|
| 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 m虏 |
| Containerized Units Supplied | 420 units (6m 脳 3m flat-pack container type) |
| Design Life | 15 years under desert conditions |
| Construction Period (On-site) | 6 weeks (26 workers + 2 site supervisors) |
The units were manufactured at 9States' production facility in Shanghai and shipped in flat-pack container format to Ras Al Khair Port via the Arabian Gulf. Total shipping volume: 78 脳 40-ft containers. From Ras Al Khair, units were trucked approximately 440 km northwest to the Wa'ad Al Shamal construction site, with the delivery phased over 3 weeks to align with the on-site foundation preparation schedule.
Each flat-pack unit was designed to be assembled by a 6-person crew using only hand tools, with no welding or heavy lifting equipment required for assembly 鈥?a critical advantage given the remote location and limited availability of skilled labor in the Northern Borders region.
With extensive experience across GCC countries, 9States understands that a standard container house is not enough for the Middle East's extreme climate. Our desert-adapted series includes:
Contact 9States today to discuss your project requirements. Whether you need a 200-person exploration camp or a 2,000-person mining accommodation complex, we deliver tailored modular solutions built for your environment.
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