CBC Flatpack Container Dormitory Project For PT Merdeka Copper Gold Tbk

CBC Flatpack Container Dormitory Project for PT Merdeka Copper Gold Tbk

Project Case Study: Customized Mining Camp Dormitories for Indonesia's Mining Giant

To support the operation of a newly developed copper mine on a remote outer island in Indonesia-where annual rainfall exceeds 2000mm and humidity remains 60%-85% year-round-CBC has successfully delivered a set of high-performance flatpack container staff dormitories in Year 2021~2022 for PT Merdeka Copper Gold Tbk (Merdeka), a leading Indonesian mining conglomerate. The project aims to provide comfortable, durable, and easy-to-transport living quarters for on-site employees, addressing the unique challenges of remote mining areas such as inconvenient transportation, harsh high-humidity and corrosive environmental conditions, and strict anti-corrosion requirements. The total project cycle from design to completion was 24 weeks, including 2 weeks to finalize the designs, 6 weeks of fabrication and packing, 6 weeks of overseas shipping & transportation and 10 weeks of on-site assembly, efficiently meeting Merdeka's urgent schedule for mine operation.

The project consists of 8 three-story flatpack container dormitory buildings, with 36 containers per building, totaling 288 container rooms. Each 2438×6000mm unit accommodates 2-4 employees, providing 1,152 beds in total to support the mine's staffing needs. Each floor houses 12 container rooms, arranged in two opposite rows with 6 rooms per row, and a 2-meter-wide corridor runs between the two rows to ensure smooth pedestrian flow. Customized steel structure stairs from CBC are installed at both ends of each building for vertical circulation. A professional light steel roofing system is also adopted to enhance the overall performance of the dormitories.

2.1 Flatpack Container Units & Detailed Material List

Founded in 2012 and listed on the Indonesia Stock Exchange in 2015 (stock code: MDKA), PT Merdeka Copper Gold Tbk is a leading Indonesian metal and mineral mining holding company headquartered in Jakarta. The company is engaged in the exploration, extraction, and production of gold, silver, copper, and other minerals, with subsidiaries operating across three islands in Indonesia, including the Tujuh Bukit Gold Mine, Wetar Copper Mine, and the newly launched Pani Gold Mine. Notably, Merdeka is developing the Tujuh Bukit Copper Project, one of the world's largest undeveloped copper deposits, and has expanded into battery materials through Merdeka Battery Materials (MBM) to supply raw materials for global electric vehicle production.

Committed to sustainable development, Merdeka has achieved an MSCI ESG rating upgrade from BBB to A in 2023, becoming the only Indonesian mining company in the MSCI Diversified Metals and Mining category to receive this rating. Its focus on operational efficiency, employee welfare, and carbon neutrality goals led to the collaboration with CBC-specifically requiring dormitories to be relocatable after 5 years of mine operation. CBC's modular solution perfectly aligns with these needs, providing reliable and adaptive living quarters for remote mine sites.

4.1 About CBC

CBC is a global leader in modular building solutions and steel structure products, specializing in providing customized, high-quality building systems for mining, construction, energy, and other industries. With rich experience in overseas projects, especially in complex environments like remote mining areas, CBC is committed to delivering one-stop solutions from design, production, packaging, to on-site guidance, ensuring project success even under challenging conditions.

4.2 Core Product Advantages

Superior Anti-corrosion Performance

Targeting the humid and corrosive environment of the Indonesian outer island copper mine, CBC adopted strict anti-corrosion processes for all components. The steel structures and container bodies undergo Sa2.5-level derusting treatment, followed by epoxy zinc-rich primer (≥80μm) and polyurethane topcoat (≥40μm) application, passing a 1000-hour salt spray test. This significantly enhances corrosion resistance, extends the service life of the dormitories, and reduces annual maintenance costs by 20% compared to conventional solutions.

Optimized Packaging & Transportation Solutions

Considering the inconvenient transportation, limited on-site infrastructure, and need for transshipment in Jakarta, CBC's SOC packaging solution stands out. By packing 4 flatpack containers into one SOC with internal steel brackets and foam padding, the project simplifies loading, unloading, and transshipment operations, reducing transshipment time by 30% and minimizing material damage risks. The robust SOC design ensures all components arrive at the project site intact, even with limited port facilities at the destination.

Efficient Modular Design

The flatpack container design allows for prefabrication of over 90% of components in CBC's factories, greatly reducing on-site construction work-critical for the mine site with no fixed construction space and unstable power supply, where only 4-5 workers per building are needed for assembly. The modular structure also enables flexible relocation after years, aligning with Merdeka's sustainable mining strategy. Additionally, CBC's solution reduces overall project cost by 35% compared to traditional reinforced concrete dormitories, balancing quality and efficiency.

Integrated System Performance & Environmental Compliance

CBC's light steel roofing system combines thermal insulation, moisture-proofing, and wind resistance. The 100mm CE-certified glass wool insulation layer regulates indoor temperature, while the building breather paper prevents moisture accumulation. Over 90% of the steel components are recyclable, and all materials meet environmental standards, aligning with Merdeka's A-level MSCI ESG rating and carbon neutrality goals. The PVDF-coated color steel tile and sturdy keel truss also ensure adaptability to local high rainfall and UV exposure.

This project not only meets Merdeka's urgent need for 1,152 beds of high-quality, relocatable employee dormitories at the new copper mine but also demonstrates CBC's strength in providing adaptive solutions for complex overseas environments. The 24-week efficient delivery, 35% cost reduction, and alignment with ESG goals have strengthened the cooperation between CBC and Merdeka, laying a solid foundation for future collaborations in more mining and infrastructure projects in Indonesia and other regions. As a model of modular building applications in remote mining areas, the project showcases the advantages of CBC's solutions in efficiency, durability, adaptability, and sustainability.