Rising Star of The Contracting Sector: Modular Buildings

The coronavirus epidemic spread rapidly all over the world and affected our lives in a very short time. This fact has led to some changes and innovations in many sectors. When we examine it on a sectoral basis, “prefabricated modular buildings”, which have been in the position of “trend topic” and widely used in many parts of the world for many years, turned into the shining star of the contracting / construction sector throughout the pandemic process.

In today’s world, many criteria such as high costs, the rapid assembly of ready-made building elements on site, eco-friendly and convertible structures, cost control, time saving, high labour costs of traditional construction methods in developed countries and challenging geographies where access to raw materials is difficult make prefabricated (pre-manufactured) modular building systems stand out rather than traditional construction techniques.

The market share of “Prefabricated Modular Buildings” is expected to reach 19.3 billion dollars in 2024 with a compound annual growth rate (CAGR) of 4.6% from 2019 to 2024.

In addition, with the traditional construction methods coming to a halt due to the Covid-19 outbreak, prefabricated modular building systems are also preferred within the framework of the following facts;

  • In modular building systems, interaction on sites is much less comparing to worker interaction in traditional project sites, since only the assembly teams work on the sites. In addition, another advantage of modular building system is minimizing the Covid-19 risks thanks to the distant and controlled production carried out at the factory environment.
  • As the epidemic is brought under control, although social distance measures are beginning to be gradually lifted by institutions such as state authorities & governmental bodies, relevant ministries that give construction decisions and approvals, private and public companies, etc. large crowds of people will not be allowed for a long time.
  • Pre-manufacturing projects can be prepared for the production of building modules. When the construction activities return to normal after the coronavirus epidemic, the production and assembly of the previously prepared modules in a shorter time makes it possible to compensate for the lost time.

When it comes to prefabricated modular structures, the first to come in mind are generally single or double-storey portable cabins, single-type containers used as worker accommodation facilities on construction sites, earthquake units, emergency units in mass displacement movements, etc.,  buildings that are established after natural disasters and emergencies and have the simplest equipment to meet the current needs or villas designed as private property with panelised system. In developing countries with rapid urbanization and developed countries such as England, Australia, Canada and USA, modular building systems are used in many sectors. Prefabricated modular buildings can be used as multi-storey buildings with developing technologies, such as hospitals, shopping malls, social and luxury residences, administrative buildings, hotels, dormitories, schools, clinics, etc.

Last year, two residential projects consisting of two 40-storey (approximately 140 meters high) towers in Singapore were built with 1,900 prefabricated modular systems. A large part of the project was produced off-site in Malaysia before the modules were placed, and then the modules were moved to the site and implemented according to a sequencing program designed to form the structure. Thus, since 50% of the project is industrialized outside the site, time loss due to bad weather conditions is minimized. Each module is produced under quality control standards, and it is possible to check before delivery, and it has been observed that the loss at the site has been reduced by around 70% thanks to such processes and methods.

Thus, it would be correct to say that prefabricated modular structures, which can be manufactured and completed off-site, can offer solutions that can fully meet the expectations, from design to the production of final modules with each passing day.

Dorce is the one of the biggest player in the market with more than 40 years of experience, offers prefabricated light gauge steel modular and pre-engineered steel construction building systems that can be designed in accordance with versatile areas of use to meet all kinds of needs with its experienced Design, Engineering, R & D and Project management teams. Dorce exports itis products in more than 60 countries on 6 continents.

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Dorce builds ‘Turnkey’ Labour Accommodation Camps for Kazakhstan Oil & Gas Sector

Today, with its proven oil reserves, Kazakhstan is among the 15 leading countries of the world, possessing 3% of the world oil reserves. Oil and gas regions of Kazakhstan cover 62% of the country’s total land and 172 oil fields are being operated. The largest oil fields of Kazakhstan are located in Tengiz, Aktobe, Atyrau, Kashagan, Karachaganak, West Kazakhstan and Mangistau and one of the largest fields in the region is Tengiz with the initial recoverable reserves of 781.1 million tons.

As a registered company in Kazakhstan, Dorce Prefabricated Building & Construction Industry Trade Inc, have been doing business in Kazakhstan and executing turnkey general contracting projects, providing EPC ( Engineering Procurement Construction) services for customers in the oil and gas and the mining industry for more than 20 years.

Dorce Inc. has secured turnkey / EPC camp projects for Tengizchevroil field, KPO BV field and AGIP field and Dorce has worked as general contractor in Shagyrly Shomyshty Gas Field, located in Mangistau region.  Dorce recently have made an appearance as the main contractor of the compressor field for the Caspian Gas project.

With the support of its enormous experinces in Kazakhstan, Dorce has developed a local content with its local supplier chain, local workforce and Dorce contiunes to contribute to economy of Kazakhstan in Oil & Gas sector.

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MSB Kara Kuvvetleri Helikopterle Taşınabilen Askeri Konteyner - Mobil Klinik Kogus Tuvalet - Savunma Sanayi

Dorce has developed airportable modular units with different usage areas

The importance and recognition of prefabricated building systems in the global market is increasing rapidly with the increasing technology and developing production systems. Dorçe carries out needs-based productions with its high production capacity, fast supply processes and logistics and assembly services for the most remote and challenging areas.

Dorçe has exclusively developed “turnkey” -transportable military camps, shelter and living spaces with helicopter in accordance with the defense industry needs. Dorçe, which allocates a serious budget to R&D (Research and Development) activities for such exclusive projects, also has a highly specialized and experienced department in its field. The R&D team forms “research and development” and “design” centers together with special units consisting of more than 70 architects, engineers, technicians and technical drawing experts working within the company. Specialized departments develop their design works using many software such as Autodesk Revit, Tekla Structures, Sap 2000 and ETAP.

The HTK (Container that can be transported by Air / Helicopter) in the images has appeared as a result of an important R&D process. Produced in 3 packages in total, HTK, was produced in a way that it can be assembled easily by hand in any environment without aid of any hand tools or equipment. 2 people can easily complete the assembly in as little as 2 hours.

These products are designed to be easily transported on air, land and sea platforms. Each unit consists of 3 packages and each package is around 300 kg. Each package can also be designed according to dimensions that can be transported by a helicopter or pickup truck. For this reason, these units developed on the basis of the defense industry, as well as oil, gas and mine exploration camps, are shipped as emergency settlement units in order to provide emergency health, shelter and food services in rural areas after natural disasters such as earthquakes, tusunami, floods all over the world.

Significant R&D and design activities have been carried out in order to ensure the use and diversity of the product, these units, as shown in the pictures below, include accommodation units (where 8 people can accommodate comfortably with folding tables and chairs), clinic (full-fledged), WC-shower (for 8 persons) are used as care and rehabilitation centers, offices and kitchens. In addition to these, special chimney and stove systems have been developed for units used in military operations in some tough geographical conditions. Step-by-step instruction manual in English and in other required languages is provided for each unit In order to complete manual assembly easily.

It is well known that prefabricated buildings can be much faster and less costly than conventional building systems. However, the HTK modules forementioned here, unlike all known prefabricated building systems and other systems, stand out in 3 aspects. The first is that it is extremely portable, the second is that it can be assembled with the help of the user manual only, and the third is that it can create a large integrated settlement area in a short time like 2 hours.

The units are equipped with alarm, heating-cooling systems, CCTV systems, security and warning systems and rapidly shipped to Africa, the Middle East, South America, Asia and Europe. These units can be transported by helicopter and can be assembled manually in any environment without aid of any hand tools or equipment and can be designed to be bullet-proof, explosion-proof in accordance with demand thanks to Dorce’s own engineering units.

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DORCE continues to offer many different solutions for the defence industry

Dorçe is the largest manufacturer of Europe on light gauge steel prefabricated structures. On the other hand, Dorce is one of the biggest 250 general contractor companies in the world according to ENR (Engineering News Record) rankings for the past 8 years.

DORCE with a combination of experience in the last two leading sectors, carries out the delivery of infrastructure, superstructure and technical equipment included turnkey military and defense projects.

Modular military structures manufactured by Dorçe, in the largest factory of Europe and the Middle East located in Ankara; includes structures such as field hospitals, emergency, border and military base areas, camp structures, military living containers, modular cabins with trailers (living, infirmary, WC-Shower), prefabricated military wards, military lodgings, regular buildings, ammunition depots, aircraft hangars, military and police training centers, containers etc that can be transported by helicopter.

In addition to military camps, Dorçe has completed projects such as fully-fledged mobile field hospitals, emergency aid units, laboratories, operating room and intensive care units, including all necessary health units and working systems.

Modular military structures are suitable for the strategic and climatic conditions of the target area; they can be manufactured in a bullet-proof, explosion-proof design and equipped with alarm, heating-cooling systems, CCTV systems, safety and warning systems.

Recently, the Air / Helicopter Containers (HTK), designed and produced by Dorçe, can be carried with helicopter and easily assembled manually in any environment, without aid of any hand tools or equipment as a result of an important R&D process. 120 modular units are produced in 1 day and made ready for shipment.

Dorçe, with general contracting services it offers in its projects as well as its manufacturer identity for more than 30 years, has also carried out many projects in the field of military and defense industry in the African continent, which is home to one of the world’s most challenging geographies.

Dorce, produces and delivers not only modular buildings but also structures consisting of pre-produced heavy steel buildings for many regions of the world. Dorçe has undertaken the design and construction work for the Japanese army in Djibouti and has also solved the F-16 aircraft type Hangar project in a very short time with heavy steel structure systems.

As part of the fight against the Covid-19 pandemic, Dorce, which produces Modular Cabins with Trailer for the Ministry of National Defense, provides fast and easy assembly by bolting these and similar modular / containerized structures to the floor and roof chassis, which allows them to be transported as partially assembled packages or fully assembled modules.

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Modüler Mobil İşçi Kampı Bursa - Mobil Prefabrik Kamp

Dorce is one of the Leading Supplier of Mobile and Portable Structures All Around The World

Nowadays, we see that “changeable and transformable” features come to the fore in the construction sector as opposed to “static and permanent” concepts.

Workers’ living camps, portable living complexes and mobile life towns which can be disassembled, rebuilt and moved, with rapidly changing living conditions and technological developments, especially in industrial areas such as oil & gas fields, mining fields and construction sites are being built which we can call “mobile and portable life”.

Mobile life / buildings offer quick and practical solutions to all the sudden and changing needs of people in the most severe climatic conditions, far away from their homes. The stable architecture, which started with the transition to permanent settlement, has begun to gave place in many areas of our lives such as education, entertainment, health services to modular mobile units which are a part of the new life culture.

In addition, the temporary accommodation and relocation situation that occurred in extraordinary situations such as natural disasters, war, refugee crises caused the rapid spread of mobile temporary living spaces, which are more practical, flexible, faster and easier accommodation method.

If we classify the modular mobile structures in general, they can be used for traditional accommodation such as caravans, modular containers, caravan-containers, temporary disaster residences, wagon-containers, modular houses as well as temporary – portable shelter in disaster areas and war zones; They are also used as temporary residences or permanent settlements at construction sites, oil & gas, mining and drilling sites and factories until the end of the work.

The most important advantage of mobile structures is to meet the physical and mental needs of disaster victims, workers, workers or migrants-refugees at short notice.

Apart from this, modular building systems are not only used in emergency settlement areas. Mobile spaces considered versatile provide many advantages to people in today’s modern living spaces. Therefore, mobile structures offer practical solutions suitable for the changing needs of people. The aforementioned structures are light gauge, easily installed and disassembled or transported from one location to another. These portable structures that are equipped with high-level technology, do not depend on a fixed location, meet their own needs and even solve their sub-structural needs such as energy recovery and waste recycling.

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DORCE is a unique player in African Region for many years

Blesssed with its rich natural resources African continent holds around %30 of the world’s known mineral reserves. Cobalt, uranium, diamonds and gold, as well as enormous oil and gas reserves.

Africa is also the world’s fastest growing region in terms of foreign direct investment by many countries and actors such as China, USA, Japan, the European Union, Russia and so on.

African construction sector is also a target destination for many economies. The availability of huge natural resources, investment opportunities in energy and infrastructure, cheap labour and fast-growing markets. Time and finance are the locomotive leverages / stimulus for the region what makes DORCE unique and reliable partner for the projects that requiring rapid solutions and high-quality services in extreme environments of the Africa.

More than 30 projects have been executed by DORCE in 17 countries across the whole region what makes the company one of the leading contractors and supplier of prefabricated steel buildings across the whole Africa.

Dorce Inc. has completed turnkey EPC Team Village Camp project for the Tasiast Gold Mine Expansion Field in Mauritania, Temporary Accommodation Facilities for Timimoun Gas Field Development Project in Algeria, fully equipped & pre-engineered hybrid steel Aircraft Hangar in Djibouti and Angondje Housing Complex of 598 units in Gabon and so many other Prefabricated Worker/Labour Camps, Prefabricated Administrative Buildings  and Containerized Modular Camp projects – served for different sectors that requiring high manufacturing capacity and experience what DORCE provides for its customers almost for more than 20 years.

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Dorce Housing Projects

One of the main product group that DORCE specialized by build-up over years along with its sector experiences is prefabricated steel houses that may appeal to low-cost, midd-class and luxury steel housing projects.

The houses build in a large high-tech warehouses at Dorce’s factory, where inclement weather conditions such as rain & snow are totally eliminated. This is done in such a way that perfect conditions enable the houses to be built quickly and smoothly.

Prefabricated Modular Steel Buildings are commonly utilized for housing projects as Dormitories, Low-cost, mid-class, luxury steel houses, family houses, dwelling-houses, apartment houses and so on.

DORCE INC. has completed many housing projects all around the world including Engineering, Building Construction Works, Civil Works, Electrical & Mechanical Works, Some Furniture Works, Foundation Works, Transportation & Custom Clearance, Landscaping and  Infrastructural Works of 598 Family Houses in Gabon only in 11 months.

Some important projects of 2 storey high-class housing and low-cost housing has been delivered for Housing and Infrastructure Board (HIB) of Libya including supply & assembly of prefabricated modular housing units with electrical and sanitary installation materials, internal and external wall paint, furniture works and transportation.

As a well-known manufacturer of prefabricated low-cost housing, mid-class and luxurious steel houses for many years, DORCE successfully delivered housing units to Australia, Iraq, UAE and Kazakhstan, with the aim of providing both affordable and peaceful living spaces for people.

Dorce offers architectural and design housing solutions that reflect the cultural heritage of each country it has been worked in.

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Usage and Benefits of Prefabricated Steel Systems for Emergency Accommodation and in Earthquake Zones

It is not possible to ignore the positive and productive contributions of the developing and constantly renewed technology of the prefabricated sector, which continues to be intertwined with the industry day by day in the world. The fact that the speed factor comes into the prominence in almost every sector today increases the preferability of prefabricated buildings.

Dorce, as a company that has proven itself in prefabricated steel structures for many years in global and local markets, is known as the largest manufacturer of Europe and the Middle East.

The world’s many countries, including Turkey, are exposed to seismic activity. Unless buildings are designed to withstand earthquake damage, significant structural damage or complete collapses can occur, especially in reinforced concrete buildings. One of the biggest reasons of this situation is that concrete is a heavy and brittle material and shows cracking and fracture reactions in sudden stresses. In this context, the lightness of steel buildings, their ability to absorb energy and ductility in sudden stresses have gained importance in the use of light steel systems as the main structural material in earthquake-resistant buildings and provides great advantages to users.

Based on experience, it has been observed that prefabricated steel structures designed in accordance with the conditions of the region perform better than reinforced concrete structures when exposed to earthquakes. Significant structural damage, collapse, as well as casualties and loss of life have been common in older masonry and reinforced concrete buildings that are not designed for earthquakes and natural disasters.

In recent years, the refugee crisis that can be called ‘top of agenda’ has serious repercussions in all political, social, economic and cultural sense not only in Turkey but also in the world. Especially refugees influxes to neighboring countries such as Turkey, and therefore the urgent need for residential housing, made the importance of prefabricated steel structures become apparent, which is defined as fast, economic and practical.

Advantages of using steel frame buildings as emergency settlement and earthquake-resistant houses:

  • Steel is safe against earthquakes. The flexibility and deformability of steel enables the structure to survive the earthquake without damage, saving lives.

 

  • Steel is the most ductile building material. What is meant by ductility? It is the ability of steel to deform a lot before it breaks or collapses. This feature provides a great advantage in terms of security in the event of an earthquake.

 

  • Systems made with steel material are more ductile than systems made with other materials. In other words, the earthquake energy absorption capacity is higher. Tensile and compressive strength are equal. For this reason, it is a good solution for systems that cannot be made with materials with lower tensile strength.

 

  • As in other building systems, assembly works are carried out at the construction site unless there is a very abnormal weather condition. For this reason, the construction period is short.

 

  • Considering the urgency and time factor after earthquakes and natural disasters, it contributes to the provision of humanitarian aid as soon as possible. It is produced quickly in production facilities and assembled in a short time and shipped as installed to the relevant field, minimizing it for the field and saving time. Only electrical and mechanical connections are made in the field of containers sent as installed.

 

  • In cases where installation is requested on site, containers or buildings are packaged in disassembled form, shipped and assembled on site.

 

  • It has a system that can be quickly disassembled, portable and reinstalled. In addition, it can be stacked on top of each other, multi-storey structures can be created and combined and intermediate panels can be removed to create much larger and more efficient living spaces.

 

  • Galvanized steel has a lifespan of 300 years when coated with coating materials from the inside and outside. Even in the most humid areas, it does not rust for years and preserves its first day resistance. Therefore, it has been determined that long-lasting steel structures resist corrosion for more than 100 years.

 

  • It is easy to renew. Provided that it is designed correctly, it is easy to make horizontal and vertical additions to the steel structure, to climb new floors and to remove certain parts. In systems with large openings, distances that cannot be crossed with other building materials can be easily covered with steel.

 

  • Due to the structure of the steel, the earthquake load that the steel will be affected by become less. The earthquake energy it has to absorb also become less.

 

  • Steel structures are much more flexible and lighter than reinforced concrete structures. Thanks to this, it is exposed to lower earthquake loads. Since the foundations will be designed for light loads, savings are made.

 

  • Steel is not only resistant to earthquakes; when adequate precautions are taken, it is also extremely resistant against moisture, lightning, fire, corrosion, storm, and harmful insects.

 

  • Steel is an environmentally friendly material that does not harm the environment during the production and use phase. It is 100% recyclable and does not leave any waste or residue. It is a building material required for sustainable construction. The Green Building defined today can be provided with steel.

 

  • The advantages that provide real comfort to the users are the ability to easily implement all kinds of classical and modern architectural projects, alternative richness in interior and exterior coatings, to meet hygiene, maintenance, renovation and change requests.

 

In the past years, Dorce, due to the major earthquake in Van, completed a total of 3,150 emergency life units for the earthquake region in a short period of 1 month and provided living space for 18,000 people. In addition, in the 2016 Çanakkale earthquake, it provided a closed and warm living space for approximately 700 people with 100 emergency settlement containers in one day.

Systems developed by Dorce with its high production capacity, design and R&D center; they have been used and continues to be used in the projects of official and private sector organizations such as the United Nations, NATO, Disaster and Emergency Ministries.

Systems developed by Dorce with its high production capacity, design and R&D center; have been used and continue to be used in the projects of official and private sector organizations such as the United Nations, NATO, Disaster and Emergency Ministries.

With these examples and more, Dorce. has been working in 52 countries and 6 continents in very difficult climatic conditions as well as political instability, civil war etc. It has demonstrated its ability to do business under humane conditions and continues to present it today in Africa, the Middle East, Central Asia, Europe and the local market.

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Dorce Prefabricated Building and Construction Industry Trade Inc. has completed prefabricated “Covid-19 Quarantine Hospital” project with a capacity of 4,000 patients in Qatar.

Dorce Prefabricated Building and Construction Industry Trade Inc. has completed prefabricated “Covid-19 Quarantine Hospital” project with a capacity of 4,000 patients in Qatar.

According to statement has been made by Dorce Prefabricated Building and Construction Industry Trade Inc, the new type of coronavirus (Covid-19) epidemic has also changed construction techniques and methods in line with the needs and requirements of construction sector. In the post-epidemic period, Covid-19 Hospitals, field hospitals, mobile hospitals, intensive care units, infection hospitals, isolation units, emergency response units and quarantine units have gained more importance than ever before. The only way to meet this global demand stands out as use of prefabricated, pre-engineered and modular building systems.

As the owner of one of the largest manufacturing facilities on light gauge steel structures in Europe, Dorce Prefabricated Building and Construction Industry Trade Inc., is actively working directly with health ministries, relevant Covid-19 authorities and non-governmental organizations for Covid Hospitals in 30 countries. The company completed its first project in this field in the Qatar / Umm Slal region. The newly completed Umm Slal Hospital was built as a fully equipped hospital to provide comfort, safety and recreation needs in addition to the healthcare services required for patients under quarantine.

As part of the emergency and preventive measures taken by the Qatari government against Covid-19, the hospital, in which the prefabricated building methodology was used, have been completed in a very short period of time. According to the statement, Umm Slal Covid-19 hospital attracts serious attention from public and private authorities of Qatar. Immediately after the opening of the hospital, which has been actively used in past weeks, Qatar Public Health Minister Dr. Hanan Mohamed Al Kuwari and the Minister of the Municipality and Environment Abdulla bin Abdulaziz bin Turki Al Subaie inspected the newly established Umm Slal Quarantine Hospital and expressed their positive opinions.

The company also gained the experience in this field after the construction of the Covid-19 quarantine hospital project, which has benn deemed with success in Qatar. Dorce Prefabricated Building and Construction Industry Trade Inc. plans to start new quarantine hospital projects in the Middle East, Africa, South America and CIS countries with the support of its high capacity manufacturing facilities.

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DORCE has completed Turnkey Camp Construction Project in Qatar

Dorce Prefabricated Building and Construction Industry Trade Inc. founded in 1982 and ranked in the ENR Top 250 International Contractors List for more than 5 years, is a Turkish general contractor with vast worldwide experience, which provides engineering, procurement and construction services for projects requiring high-quality services in extreme environments.

Dorce Inc. is a registered company in Qatar for many years since it has successfully completed two-large scale projects for the Oil & Gas sector of Qatar, which constitute the backbone of Qatar’s Economy. Turnkey Labor camps, with the approximate capacity of 20.000 persons, are located in most important industrial locations of Qatar; Ras Laffan Industrial City & Masaieed Industrial City. Nowadays, Dorce Inc. continues to provide its high-quality services and share its know-how in Doha for the project of the Ministry of Municipality & Urban Planning – Qatar (MMUP). Integrated Workers Accommodation Camp for 4.000 persons is located in Doha.

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Dorce Prefabricated Building & Construction Industry Trade Inc. is a Turkish General Contractor with a vast worldwide experience, which provides Engineering, Procurement & Construction (EPC) services for projects requiring high-quality services in extreme environments. Dorce owns one of the largest prefabricated steel structure manufacturing facilities in the world. The manufacturing facility located in Ankara – Turkey.

DORCE Prefabricated Building and Construction Industry Trade Inc. is a leading company in the World on manufacturing of prefabricated steel structures, execution of general contracting projects and completion of TURNKEY projects for clients in Oil&Gas and Energy industry, Mining Industry, Construction Industry, Governmental Authorities (Ministries, Governorates, Embassies etc.), Militaries, International and non-profit Organizations, etc. in more than 50 countries.

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