KOROK Access Panel – Safe Removal & Reinstallation Procedure

 

⚠ WARNING – HEAVY PANEL

  • 480 mm x 480 mm (~27 kg)!
  • 600 mm x 480 mm (~33 kg)!
  • 900 mm x 480 mm (~50 kg)!

IN ACCORDANCE WITH NEW ZEALAND HEALTH & SAFETY REQUIREMENTS

  • Weight: This panel is heavy and may cause serious injury if not handled correctly.
  • Team Lift Mandatory: Always use at least two people or appropriate mechanical lifting equipment.
  • Wear Proper PPE: Use gloves, safety footwear, and any other required personal protective equipment.
  • Follow Lifting Procedures: Ensure you follow all site-specific and WorkSafe New Zealand guidelines, including a proper risk assessment before lifting.
  • Secure Installation: Confirm that the panel is securely supported during movement and installation.

Failure to use correct lifting methods and PPE may result in severe injury or property damage.

  • Applicable Panel Type: Fire-Rated Ceiling Access Panels
  • Panel Weight: Heavy (Team lift required)
  • PPE Required: Gloves, safety boots, hard hat, safety glasses

STEP 1. PREPARATION & SAFETY CHECKS

  1. Ensure all relevant site safety protocols and WorkSafe NZ guidelines are followed.
  2. Review the access panel warning label and lifting instructions prior to beginning.
  3. Conduct a job safety analysis (JSA) or task risk assessment.
  4. Inspect the work area for overhead hazards and confirm safe clearance for panel lowering.
  5. Confirm required PPE is worn and in good condition.
  6. Gather appropriate tools:
    • Socket set or spanners
    • Mechanical lifting aid (optional but recommended)
    • Clean drop cloth or secure storage pallet

STEP 2. SUPPORTING THE PANEL

  1. Before any bolts are loosened, ensure the panel is securely supported by:
    • Two competent personnel (manual lift), or
    • An approved mechanical lifting device.
  2. Support the panel from beneath to prevent any unplanned movement.

STEP 3. BOLT REMOVAL PROCEDURE

  1. Remove all perimeter bolts, retaining one bolt at each angle line to maintain panel stability.
  2. Do not remove any screws or TEK-type fasteners that:
    • Secure the panel frame to the hatch, or
    • Secure support angles to the ceiling C-track structure.

STEP 4. PANEL REMOVAL

  1. Once weight is fully supported and remaining bolts are accessible, remove the final two bolts.
  2. Carefully lower the panel straight down, ensuring no twist or torque is applied to the frame.
  3. Immediately place the panel on a prepared soft surface or pallet to avoid damage.
  4. Store panel in a secure, dry, and protected area free from impact risk.

STEP 5. CONDITION INSPECTION (PRE-REINSTALLATION)

Perform a full visual and physical inspection of the following components:

  1. Hatch door surface for warping, dents, or cracks
  2. Frame integrity including weld points and connection tabs
  3. Intumescent seal – check for continuous seal and any cracking or displacement
  4. Promatect® fire board – check for chipping, delamination, or moisture ingress

Replace any damaged or non-compliant components before proceeding with reinstallation.

STEP 6: REINSTALLATION PROCEDURE

  1. Position the access panel under the aperture using team lift or lifting device.
  2. Align the panel with the original bolt holes and insert bolts at each angleline.
  3. Once Securing nut and bolt assemblies are secured, reinstall remaining bolts in a crisscross pattern to ensure even loading.
  4. Torque all fasteners to manufacturer-recommended specification if available.
  5. Visually verify that the panel is flush with the ceiling and that all mechanical fixings are secured.

If you have any questions, please contact KOROK

info@korok.com or visit www.korok.com