SmartSteel Buildings delivered a modern 5-bay commercial workshop for Northland Toyota, designed to support a high-volume automotive operation. The facility incorporates vehicle preparation bays, hoist-ready service areas, and a layout optimised for efficient workflow and professional presentation.

As part of the building envelope, KOROK® supplied high-performance external wall solutions to meet the demanding requirements of durability, safety, and acoustic control typical of busy automotive environments.

KOROK® Contribution

KOROK® provided 108m² of KOROK® 78mm Colour Panel, installed as part of the KOROK® External Wall System.

The KOROK® External Wall System is a non-loadbearing vertical wall solution engineered for commercial and industrial applications. It combines:

• A zinc-coated COLORSTEEL® outer shell for durability and weather protection
• A high-density (400 kg/m³) aerated concrete core for fire resistance and acoustic insulation

This all-in-one system delivers fire rating, acoustic performance, and weather-tightness within a single assembly. The system uses 78mm interlocking panels installed vertically to create a continuous protective barrier, limiting acoustic leakage while maintaining fire integrity.

Outcome

The integration of the KOROK® External Wall System ensured that the Northland Toyota workshop achieved:

• High fire safety standards for commercial compliance
• Improved acoustic performance, supporting a more controlled working environment
• Durability suited to demanding industrial use
• Efficient construction timelines, aligning with Smart Steel’s delivery goals
• Modern, professional aesthetics

This project demonstrates how KOROK® contributes to high-performance building outcomes by supporting safer work environments, efficient project delivery, and long-term durability and reliability, working alongside SmartSteel Buildings to deliver a facility that reflects the operational excellence and brand strength of Northland Toyota.

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132 Halsey Street is a high‑end waterfront residential development in Auckland’s Wynyard Quarter, comprising 51 luxury apartments with ground‑floor retail. Designed by Athfield Architects and delivered by Haydn & Rollett, the project presented significant complexity, including reclaimed land, a multi‑slab basement below sea level, and bespoke apartment layouts within a tight urban site.

The development was instrumental in establishing the NZGBC Homestar Multi‑Residential tool, achieving 7‑ and 8‑star ratings for both design and as‑built performance.

Supporting Efficiency on a Challenging Site

Given the constrained waterfront location and concurrent construction activity across Wynyard Quarter, efficient material handling and installation were critical. The lightweight nature of KOROK panels eased transport to upper levels and simplified on‑site handling, particularly beneficial in a multi‑storey environment with limited laydown space.

Minimal on‑site modification requirements further reduced labour time and potential delays, supporting Haydn & Rollett’s need to problem‑solve effectively while maintaining a high standard of finish throughout the project.

KOROK Technical Contribution

KOROK supplied fire and acoustic rated wall systems for critical building infrastructure, including lift shafts, risers and ducts, where performance, efficiency and buildability were paramount.

KOROK® 78mm panels are precision roll‑formed from high‑quality zinc‑coated steel meeting AS/NZS 1397:2001, with a 0.4 mm base metal thickness and Z275 coating, enclosing a lightweight aerated concrete core. With a nominal weight of just 10.2 kg per lineal metre, the panels provided an ideal balance of strength, durability and handling efficiency. This lightweight yet robust construction made the panels ideal for multi‑storey installation in a constrained waterfront environment.

A Benchmark Outcome

Together with neighbouring developments, 132 Halsey Street played a pivotal role in shaping the NZGBC Homestar Multi‑Residential tool, achieving 7‑ and 8‑star Homestar ratings across both design and as‑built categories. The integration of high‑performance building systems—including KOROK’s fire and acoustic solutions—contributed to the project’s overall environmental and technical success.

Today, 132 Halsey stands as one of Auckland’s most exclusive waterfront residential addresses: a development that engages seamlessly with its public realm, delivers exceptional living environments, and sets a new benchmark for sustainable, high‑quality urban living.

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Arahia is a five-townhouse development on a compact urban site, requiring precise coordination between architectural intent, spatial efficiency, and regulatory performance. The design comprises two-level white bagged brick volumes stepping up the site, with interstitial garages providing clear articulation between units while supporting privacy and rhythm along the façade. Dense landscaping reinforces separation between dwellings and circulation zones. Central to the project was the performance of the intertenancy walls, which needed to meet fire, acoustic, and spatial requirements without adding construction complexity or compromising internal floor area.

The Challenge: Intertenancy Performance Without Compromise

As with many terraced housing developments, intertenancy walls at Arahia needed to achieve more than structural separation. The walls were required to:

• Meet stringent fire resistance requirements for attached dwellings
• Deliver strong acoustic performance to support quiet, comfortable living
• Be space-efficient, preserving valuable internal floor area
• Integrate seamlessly with a modern construction programme

Meeting all of these criteria within a compact building envelope demanded a system that was robust, compliant, and efficient to install.

KOROK® Intertenancy Solution

KOROK supplied 290m² of KOROK® 51mm Galv Panels, installed as part of the KOROK® Intertenancy Terraced Housing System.

The system delivers a -/60/60 Fire Resistance Rating, suitable for intertenancy walls in terraced housing and fully compliant with the New Zealand Building Code (NZBC). Unlike conventional framed and lined systems, the KOROK® panel itself forms the primary fire barrier, providing inherent durability and long-term resilience.

Panels are positioned between double wall frames and connected via aluminium brackets engineered to respond predictably in fire conditions—allowing the fire-exposed side to detach while maintaining the integrity of the barrier on the protected side.

KOROK® for Modern Terraced Housing

The Arahia project demonstrates how KOROK® Intertenancy Systems are well suited to contemporary townhouse developments—where protection, performance, and efficiency must coexist. By combining engineered fire resistance, acoustic control, and slimline design, KOROK continues to support safer, smarter, and more liveable medium-density housing across New Zealand.

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Project Maunga is the major redevelopment of Taranaki Base Hospital, delivering future‑focused healthcare facilities for the Taranaki region. The project sets new benchmarks for healthcare design, targeting Zero Energy and Zero Carbon certification through the International Living Future Institute (ILFI), while maintaining the rigorous fire, acoustic, and infection‑control standards required in a hospital environment.

Architectural Vision & Performance

Designed by Warren and Mahoney Architects, This project challenges traditional perceptions of hospital environments. The single‑level building prioritises accessibility, patient dignity, and clinical efficiency, while feeling more like a community clinic than a hospital.

After accounting for carbon‑sequestering materials, the building achieves a net upfront embodied carbon of –126 kg CO₂e/m², making it one of the first healthcare facilities globally to achieve a net‑negative carbon outcome.

Why KOROK® Was Chosen

KOROK® systems delivered the required fire resistance and acoustic performance for lift shafts, risers, and ducts, supporting patient safety, comfort, and regulatory compliance in a healthcare environment, while also enhancing construction efficiency. The system contributed to reduced construction time, and minimised programme risk.

• 813 m² of KOROK® 78 mm Galvanised Panels
• Applications: lift shafts, service risers and services ducts

The KOROK® 78 mm Galv Panel offered several advantages aligned with the project’s requirements:

• Fire and acoustic performance: Providing compliant fire separation and acoustic control essential for hospital service zones.
• Lightweight, high‑performance construction: Precision roll‑formed from AS/NZS 1397:2001 compliant zinc‑coated steel with a lightweight aerated concrete core, delivering strength at a nominal weight of just 10.2 kg per lineal metre.
• Efficient installation in confined spaces: Single‑side installation reduced the need for internal scaffolding within shafts, improving safety and construction efficiency.
• Reduced programme risk: Faster installation and minimal on‑site modification supported delivery within a complex, live hospital environment.

Outcome

The integration of KOROK® fire and acoustic rated wall systems supported the delivery of a world‑leading healthcare facility – one that combines sustainability leadership, patient‑centred design, and robust technical performance. At Taranaki Base Hospital, KOROK® has contributed to a building that is not only safe and durable, but also aligned with the project’s wider vision of resilience, efficiency, and long‑term environmental responsibility.

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Hiwa – The University of Auckland Recreation Centre is a landmark, vertically stacked wellness facility at the heart of the university’s student precinct. Designed to support physical, social, and mental wellbeing, the 20,000 m² building responds to a constrained urban site through an innovative split-level configuration organised around a central fitness core. Since opening, Hiwa has become a major hub of campus life, with over 500,000 visits in its first months. KOROK contributed to this nationally and internationally recognised project by supplying high-performance fire and acoustic wall systems for lift shafts, risers, and service ducts, supporting both the building’s technical and architectural ambitions.

 Technical Challenge

The project faced significant technical complexity due to its eight-level vertical stacking, requiring robust fire separation between lift shafts, risers, and occupied spaces. Construction occurred within a tightly constrained urban site, limiting access and traditional installation methods, while extensive service coordination was required across stacked programme zones. These challenges demanded a wall system that could deliver certified fire and acoustic performance without adding unnecessary weight, complexity, or installation time—particularly for multi-storey shaft construction.

Why KOROK Was Specified

KOROK was specified to support the project’s fire safety strategy while simplifying construction within confined vertical spaces. The KOROK® lift shaft, riser, and duct systems offered several advantages aligned with the project’s requirements:

• Single-side installation, eliminating the need for internal scaffolding within shafts
• Proven fire and acoustic performance, essential for large, publicly occupied buildings
• Lightweight construction, reducing load impacts on the stacked structure
• Speed and efficiency, supporting programme certainty in a complex build environment

For a project of this scale and intensity, the ability to install from one side only was particularly valuable, improving safety, access, and sequencing across multiple floors.

System Selected

The project utilised KOROK® Lift Shafts, Risers & Ducts systems, constructed with KOROK® 78mm Galv Panels.

The panels are precision roll‑formed from high‑quality zinc‑coated steel in accordance with AS/NZS 1397:2001 standards and house a lightweight aerated concrete core. With a nominal weight of approximately 10.2 kg per lineal metre, the panels provided excellent handling characteristics while maintaining structural integrity and high-performance fire and acoustic outcomes.

This system was particularly well suited to the vertical nature of the building and the high level of service coordination required throughout the facility.

Benefits, Compliance & Performance Outcomes

KOROK systems at Hiwa delivered compliant, high‑performance fire and acoustic solutions for lift shafts, risers, and ducts, supporting both occupant safety and user comfort. The BRANZ‑appraised systems provided confidence in compliance, reduced consenting risk, and aligned seamlessly with the project’s advanced fire engineering strategy. Fast, single‑sided installation improved programme certainty and coordination within the vertically stacked building, while long‑term durability ensured reliable performance for this landmark education facility.

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The Sands Stage 1A is the first completed phase of The Sands Town Centre in Pāpāmoa, a major master‑planned commercial development in the Bay of Plenty. Completed in 2024, the project includes a New World supermarket and a mixed‑use retail block, delivered concurrently on a greenfield site. Livingstone Building acted as ECI Contractor alongside Bluehaven Commercial, delivering approximately 4,901m² of space including supermarket and multiple tenant fit‑outs. This stage represents the fifth collaboration between Livingstone and Bluehaven and forms part of the first of three planned stages for the wider development.

Why KOROK Was Specified

KOROK was specified for its proven performance in commercial and industrial environments where reliable fire and acoustic separation is critical. Its independently tested and appraised systems provided confidence to the project team, while the modular, prefabricated panel design supported efficient on‑site coordination and consistent, verifiable performance outcomes aligned with construction and programme requirements.

The project used 78mm KOROK galvanised panels as a non‑loadbearing internal wall solution across supermarket and retail tenancies. The system delivers a robust combination of fire resistance and acoustic control for intertenancy and back‑of‑house areas, using interlocking steel‑faced panels with an aerated concrete core that can be installed vertically or horizontally to suit the building layout.

Technical Challenge

As a large‑format supermarket and multi‑tenancy retail development, the project required internal wall systems that could provide effective fire separation and acoustic control across a range of occupancies. These performance requirements were essential to meeting regulatory obligations while supporting the differing operational needs of both anchor and specialty tenants.

Compliance + Performance

KOROK Warehouse and Retail Systems are developed to recognised New Zealand Standards and supported by BRANZ testing and appraisal. On this project, the system delivered compliant fire resistance, effective acoustic performance, and reliable non‑loadbearing structural performance, providing confidence in regulatory compliance and supporting a smooth consenting and delivery process for a complex mixed‑use commercial development.

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KOROK® Fire and Acoustic Solutions Elevate a World-Class Arts Venue

The Waikato Regional Theatre is set to become a landmark for Hamilton and the wider Waikato region, bringing world-class performing arts, cultural vibrancy, and community engagement to the city centre. After six years of planning and collaboration, construction began in November 2021, with completion expected in 2025. KOROK® was proud to contribute to this transformational project, providing innovative fire and acoustic wall solutions that underpin both safety and sound quality.

KOROK® Contribution: Cinema-Grade Walls for Exceptional Performance

KOROK supplied 3,000 m² of our 78mm Galv Panel for the theatre, incorporating our specialised Cinema Systems designed specifically for performing arts venues. Each KOROK® 78mm Galv Panel is rollformed from zinc-coated steel strips, featuring a 0.4 mm base metal thickness and Z275 zinc coating, with an aerated concrete core weighing approximately 10.2 kg per lineal metre. These panels combine lightweight construction with superior acoustic and fire performance, making them ideal for auditoriums and rehearsal spaces.

Our systems deliver superior soundproofing, ensuring minimal sound transmission between performance spaces, enhancing the experience for audiences while meeting stringent fire safety standards. With a proven track record across cinema and theatre projects, KOROK® provides trusted, reliable solutions for both fire protection and acoustic performance.

Supporting a Heritage-Led, Community-Focused Project

The Waikato Regional Theatre has been designed as an arts-led urban regeneration project, reconnecting Hamilton’s city centre with the Waikato River. The theatre integrates the retained façade of the historic Hamilton Hotel, incorporates heritage elements and native timbers from the original building, and will feature a 1,300-seat lyric theatre capable of operating in both theatre and orchestra modes.

By installing KOROK® fire- and acoustic-rated walls, the project benefits from enhanced safety for visitors and staff, as well as controlled acoustics critical to both performances and audience enjoyment. KOROK’s lightweight, prefabricated systems complemented the architect’s use of mass timber for the auditorium roof, blade walls, catwalks, and bleachers, supporting the project’s ambitious programme while delivering practical fire and acoustic solutions.

Why KOROK® Was Chosen

Hamilton’s new theatre required walls that could handle high acoustic demands, strict fire compliance, and fast, efficient installation. KOROK® provided:

• High Fire Resistance: Fully compliant with New Zealand building code requirements, ensuring the safety of audiences, performers, and staff.
• Proven Acoustic Performance: Minimal sound transfer between spaces, delivering an immersive and high-quality performance experience.
• Efficient Installation: Lightweight panels with clip-together simplicity allowed for rapid assembly on a complex, multi-material project.

By integrating KOROK® systems into the Waikato Regional Theatre, the venue benefits from both technical performance and long-term reliability, supporting the vision of a cultural hub that will serve Hamilton and the Waikato region for decades.

Building a Legacy with KOROK®

From safeguarding audience experiences to supporting the acoustic integrity of performances, KOROK® has played a key role in making the Waikato Regional Theatre a safe, world-class venue. This project underscores KOROK’s expertise in delivering fire and acoustic solutions for complex, high-profile buildings, from cinemas to performance spaces, helping communities thrive through innovative and trusted wall systems.

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Parakiore Recreation and Sports Centre stands as one of Aotearoa New Zealand’s most ambitious community and high-performance sporting developments – a 32,000m² hub designed to support everyday recreation through to elite national and international events. Designed by Warren and Mahoney in association with Peddle Thorp and MJMA, and delivered on behalf of Crown Infrastructure Delivery for Christchurch City Council, the project required building systems that could perform at the highest level – structurally, acoustically, and in fire protection. KOROK was proud to contribute to this nationally significant development, supplying 300m² of KOROK® 78mm Galv Panel for key internal fire and acoustic separations within the complex.

The Challenge: Performance Across Scale, Safety & Sound

A building of this scale brings significant fire-safety and acoustic requirements. With large wet and dry zones, interconnected public spaces, high-performance training areas, and major event facilities, the project team required internal wall systems that delivered:

• High fire resistance for critical separation zones
• Reliable acoustic performance to manage noise transfer between pools, courts, fitness areas, and specialist spaces
• Lightweight construction to integrate efficiently into the steel-driven structural design
• Durability and compliance within a major civic facility expected to host two million visitors annually

This combination of acoustic control, fire protection, and constructability made KOROK’s systems an ideal fit.

KOROK® Solution

KOROK supplied 300m² of KOROK® 78mm Galv Panels, providing a robust fire- and acoustic-rated solution for internal separations within the facility. Why the 78mm Galv Panel Was Chosen:

• High-Performance Fire Rating. Manufactured from zinc-coated steel shells conforming to AS/NZS1397:2001 with a Z275 coating, the panels offer reliable and tested fire protection essential for a public facility of this scale.
• Excellent Acoustic Control. The aerated concrete core delivers strong airborne sound reduction — critical in a building that includes hydroslides, aquatic halls, gym spaces, and nine active courts.
• Lightweight & Efficient to Install. At just 10.2kg per lineal metre, the 78mm panel is easily handled on a complex construction site, allowing rapid installation and smoother coordination with other trades.
• Durability for Heavy-Use Environments. Designed to stand up to the demands of high-traffic public recreation centres and high-performance training areas.

The KOROK system contributed to meeting the project’s stringent fire-safety requirements while supporting the acoustic conditions necessary to create a functional and enjoyable environment across vastly different activity zones.

KOROK’s contribution helped ensure safe, durable, and high-performing internal environments within one of New Zealand’s most significant sport and recreation developments. The Parakiore facility will host community users, school groups, local clubs, and elite athletes alike – supported by dependable fire and acoustic separation systems designed to perform over decades of intensive use. KOROK is proud to support a project that not only enhances Christchurch’s sporting infrastructure but also delivers long-term social, economic, and recreational benefit for the region.

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The highly anticipated IKEA Auckland has officially opened its doors – marking the Swedish retailer’s first store in New Zealand and a major milestone for the Sylvia Park precinct.

Spanning 34,000 m², the store is the size of three rugby fields and was designed to deliver IKEA’s global retail experience while meeting New Zealand’s seismic and building performance standards. Developed by Kiwi Property Group and constructed by Naylor Love, the store opened in December 2025, just in time for the busy Christmas season.

KOROK’s Contribution

KOROK® was proud to play a key role in the construction of New Zealand’s first IKEA, supplying approximately 5,500 m² of our 78mm Gen 2 Fire and Acoustic-Rated Wall Systems.  Our panels were used as part of the KOROK® External Wall Systems (Factory & Warehouse System) – providing the strength, speed, and performance required for such a large-scale commercial facility.

Collaboration and Delivery

The project was managed and built by Naylor Love, who also oversaw mental health and safety initiatives on site through MATES in Construction accreditation – promoting wellbeing across the workforce. Designed by Australian architects, the Auckland IKEA incorporates enhanced seismic resilience, setting a new benchmark for large-format retail design in New Zealand.

Project Outcome

The completion of IKEA Auckland represents a significant achievement in New Zealand’s construction and retail sectors. The store showcases a blend of Swedish design principles and Kiwi engineering expertise, delivered through a collaborative effort across the project team.  KOROK® is proud to have contributed to this landmark development, helping ensure the store’s fire safety, acoustic performance, and long-term durability – all while supporting efficient construction and high-quality results.

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Project Overview
Air New Zealand’s Hangar 4 is the Southern Hemisphere’s largest single-span timber aircraft hangar, designed to simultaneously accommodate a widebody Boeing 787-9 Dreamliner and two Airbus A320/A321 aircraft. The facility includes hangar space alongside workshops and engineering areas, all designed with sustainability, operational efficiency, and safety in mind.

KOROK’s Role
KOROK Building Systems supplied KOROK® External Wall Systems for Hangar 4, delivering a complete solution for fire-rated, acoustic-rated, and weatherproof external walls. These systems were essential for providing safe, durable, and efficient separation across hangar and workshop areas, while withstanding New Zealand’s unique environmental conditions.

Project Highlights

• Panels integrated seamlessly with the massive timber trusses, minimizing additional structural load.
• All-in-one design simplified construction and accelerated the project timeline.
• Fire and acoustic performance created a safe and productive working environment for Air New Zealand engineers.

Outcome
KOROK® External Wall Systems and 78mm Colour Panels supported Hangar 4 in achieving world-class standards in fire safety, acoustic separation, and weather resilience. The lightweight, durable, and efficient solution complemented the innovative mass timber construction, helping create a safe, functional, and sustainable aviation maintenance facility.

Products Used

• KOROK® External Wall Systems: All-in-one solution for external walls, offering fast installation, fire and acoustic protection, and weatherproof durability without the need for cranes or engineered slabs.
• 78mm KOROK® Colour Panels: Lightweight yet high-performance panels with a COLORSTEEL® steel shell and aerated concrete core, providing superior fire and acoustic protection while complementing the External Wall System.

Key Benefits Delivered

• Lightweight & Cost-Effective: Reduced installation time and material costs.
• Rapid, Simple Installation: Small installation teams managed wall construction efficiently.
• Fire & Acoustic Efficiency: Enhanced safety and operational comfort in hangar and workshop spaces.

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