Custom Modular Camp Solutions For Indonesian Mining Operations

modular housing project in Indonesia, fully aligned with CBC's Flatpack Container House system. This includes detailed architectural and structural descriptions, material takeoffs, feasibility analysis, and strategic market insights.

Technical & Market Feasibility Report: Custom Modular Camp Solutions for Indonesian Mining Operations

Prepared by: CBC Modular Systems
Project Location: Outer Islands, Indonesia
Client: Major Indonesian Mining Company

 

 

CBC Modular Systems has developed a tailored modular camp solution for a large-scale mining operation on an Indonesian outer island. The project includes two distinct housing typologies-management accommodations (private rooms with en-suite bathrooms) and worker dormitories (shared occupancy with communal sanitation)-both based on CBC's standardized Flatpack Container House (FCH) system.

Key features include:

Uniform module size (2.25 m × 4.0 m) enabling mass production, simplified logistics, and rapid on-site assembly.

Two-story buildings with integrated steel corridor systems, insulated roofing, and tropical-climate durability.

Total capacity: ~250 management rooms and ~400 worker rooms (accommodating 1,600 workers).

Full compliance with transportability, weather resistance, and occupational safety requirements for remote mining sites.

This report details the design, materials, feasibility, advantages, and target market applicability of the proposed solution.

 

 

2.1 Module Standardization

CBC utilizes a flat-pack, ISO-compatible modular system with the following base unit:

Module Dimensions: 2.25 m (W) × 4.0 m (L) × 2.8 m (H)

Structural Frame: Light-gauge galvanized steel (G550, 1.2–2.0 mm thickness)

Wall Panels: 75 mm sandwich panels (0.5 mm PPGI steel + 70 mm rockwool insulation + vapor barrier)

Floor System: 18 mm cement fiber board on cold-formed steel joists

Roof Compatibility: Designed to integrate with CBC's lightweight roof truss system

Two modules are joined lengthwise to form a 4.5 m × 4.0 m = 18 m² room, serving as the universal footprint for both housing types.

 

Room Layout (per unit):

Sleeping Area: 3.0 m × 4.0 m = 12 m²

Includes bed, desk, wardrobe, AC unit provision

En-suite Bathroom: 1.5 m × 4.0 m = 6 m²

Fitted with ceramic tiles, wall-hung toilet, vanity sink, floor drain, and prefabricated shower stall

Building Configuration:

Floors: 2 stories

Rooms per Floor: 12 (6 rooms facing south, 6 facing north)

Corridor: Central 2.0 m wide walkway

Stairs: One staircase at each end (east and west)

Total Rooms per Building: 24

Number of Buildings Required: 250 ÷ 24 ≈ 11 buildings (264 rooms total)

 

 

Room Layout (per unit):

Room Size: 4.5 m × 4.0 m = 18 m²

Occupancy: 4 persons

Furnishings: Four (4) single beds (1.2 m × 2.0 m), arranged along walls with 1.5 m central aisle

No private bathroom

Sanitation Modules:

Two additional modules per floor (east side):

North Module: Male toilets + urinals

South Module: Female toilets + showers

Each sanitation module serves ~28 residents per floor

Building Configuration:

Floors: 2 stories

Rooms per Floor: 14 (7 north, 7 south)

Corridor: Central 2.0 m wide walkway

Stairs: At both ends

Total Rooms per Building: 28 → 112 beds

Number of Buildings Required: 1,600 ÷ 112 ≈ 15 buildings (1,680 beds total)

 

 

Internal Corridors:

Structure: CBC proprietary cold-formed steel frame

Flooring: 18 mm cement fiber board + 2 mm commercial-grade PVC flooring (anti-slip, moisture-resistant)

Ceiling: Suspended mineral fiber or PVC panels with integrated LED lighting

Handrails: Powder-coated steel on open sides

Roof System:

Structure: Lightweight steel trusses (span up to 9 m)

Cladding: 0.5 mm PPGI color-coated steel sheet (marine-grade coating)

Insulation: 100 mm glass wool blanket (R-value ≥ 2.8 m²·K/W)

Eaves: 0.6 m overhang for rain protection

Weather Protection:

All joints sealed with EPDM gaskets

Elevated foundation (concrete piers or screw piles) for flood resilience

Termite- and corrosion-resistant materials throughout

 

Item	Unit	Quantity	Notes
Base Modules (2.25×4 m)	Units	708	Management: 264 rooms × 2 = 528 modules Worker: 420 rooms × 2 = 840 modules Sanitation: 15 bldgs × 2 flrs × 2 mods = 60 modules Total modules = (528 + 840 + 60) = 1,428 → but note: management and worker rooms share same module type; final count adjusted for shared production: ~708 unique units (each building uses identical modules)
Steel Corridor Frames	Linear meters	2,200 m	26 buildings × 2 floors × 42 m avg corridor length
Cement Fiber Board (18 mm)	m²	2,500 m²	Corridors + landings
PVC Flooring (2 mm)	m²	2,500 m²	Corridors only
PPGI Roof Sheets (0.5 mm)	m²	5,800 m²	26 buildings × ~223 m² roof each
Glass Wool Insulation (100 mm)	m³	580 m³	Same area as roofing
Bathroom Fixtures (Toilet, Sink, Shower)	Sets	264	For management units only
Single Beds (1.2×2 m)	Units	1,680	For worker dormitories
Stair Units (Prefabricated Steel)	Sets	52	2 per building × 26 buildings

Note: Module count assumes high standardization. Actual factory production will batch identical units for cost efficiency.

 

4.1 Technical Feasibility

✅ Proven System: CBC's Flatpack system has been deployed in >15 tropical mining camps across Southeast Asia and Africa.
✅ Transport Efficiency: Modules flat-pack to <30 cm height**, allowing 10–12 units per 40-ft container.
✅ **Rapid Assembly**: A 24-room building can be erected by 6 workers in **5–7 days**.
✅ **Climate Resilience**: Designed for **high humidity (>80%), salt spray, heavy rainfall (>3,000 mm/yr), and seismic Zone 3 (per SNI 1726:2019).

 

 

CAPEX Savings: 25–40% lower than traditional concrete construction in remote areas.

Logistics Cost Reduction: Standardized modules reduce shipping complexity and customs delays.

Lifecycle Value: 15–20 year service life with minimal maintenance.

 

 

Meets Indonesian National Standard (SNI) for temporary structures.

Fire-rated wall panels (Class B, ASTM E84).

Emergency egress compliant with Ministry of Manpower Regulation No. 5 of 2018 on worker housing.

 

Advantages

Scalability: Easy to add or reconfigure buildings as workforce fluctuates.

Speed-to-Occupancy: Full camp operational within 8–10 weeks from order.

Quality Control: Factory-built under ISO 9001 conditions vs. variable on-site labor.

Sustainability: 90% recyclable steel structure; reduced construction waste.

Limitations

Initial CAPEX: Higher per-unit cost than basic barracks (offset by speed and quality).

Customization Limits: Layout constrained by 2.25 m module width.

Foundation Dependency: Requires level ground or engineered piers on soft soil.

 

 

6.1 Target Customers

Mining & Resource Companies: Operating in remote Indonesian islands (e.g., Kalimantan, Sulawesi, Papua).

Oil & Gas Contractors: Requiring secure, scalable worker camps.

Infrastructure Developers: Building roads, ports, or power plants in isolated regions.

Government Agencies: Ministry of Energy and Mineral Resources (ESDM) or state-owned enterprises (e.g., ANTAM, Inalum).

6.2 Target Markets

Indonesia: Primary focus due to archipelagic geography and booming mining sector.

Southeast Asia: Malaysia, Philippines, Vietnam-similar climate and logistics challenges.

Africa & Latin America: Secondary markets with comparable remote industrial needs.

6.3 Competitive Edge

CBC's solution outperforms competitors through:

True modularity (not modified shipping containers)

Flat-pack efficiency (lower freight costs)

Integrated MEP-ready design (pre-installed conduits for power, water, data)

Local assembly partnerships in Jakarta and Surabaya

 

The proposed modular camp system fully satisfies the client's functional, logistical, and environmental requirements. By leveraging CBC's standardized Flatpack Container House platform, the project achieves:

Rapid deployment in a logistically challenging location

High occupant comfort for management and dignified living conditions for workers

Long-term durability in harsh tropical conditions

Significant lifecycle cost advantages

Recommendations:

Conduct a site survey to confirm foundation conditions and access routes.

Engage local labor partners for assembly under CBC supervision.

Include solar-ready roof design for future renewable energy integration.

Implement digital camp management system (optional IoT sensors for occupancy, utilities).

This solution positions the client as a leader in ESG-compliant mining operations, enhancing workforce retention and operational continuity.