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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CASE STUDY

Indigo Hotel & Apartments

KOROK is proud to have contributed to one of Auckland’s most distinctive new developments — the Indigo Hotel and Apartments at 51 Albert Street. This iconic project brings together a 4.5-star lifestyle hotel, luxury branded residences, and vibrant food and beverage offerings, all within a uniquely challenging site: a slender 41-storey tower rising from a historic 1912 heritage façade.

Designed by Scott Carver and Dalman Architects and delivered by ICON Construction, the Indigo Hotel and Apartments is a shining example of how careful planning, construction innovation, and respect for heritage can work hand in hand to create a new city landmark.

The Challenge

The development’s highly constrained inner-city site presented several key construction challenges:

• A tight building footprint within a heritage-listed façade.
• Stakeholder sensitivities, with close proximity to neighbouring residents, businesses, and the historic St Patrick’s Cathedral.
• The need for high productivity and precision construction techniques on a vertical build of this scale.

ICON Construction’s advanced project management systems and meticulous construction methodologies ensured these challenges were met head-on, delivering an exceptionally efficient build process.

KOROK’s Solution

To meet the stringent fire and acoustic performance requirements across the tower’s external walls, risers, and duct systems, KOROK supplied our 78mm fire and acoustic rated panel system.

Our panels were selected for their:

• Lightweight nature, critical for high-rise construction.
• Exceptional fire protection performance for vertical service penetrations and separation zones.
• Superior acoustic insulation, ensuring a premium experience for both hotel guests and apartment residents.
• Rapid installation advantages, helping ICON maintain construction momentum within a tight delivery program.

As a pre-finished system, KOROK panels also contributed to reducing on-site finishing work, a key benefit on a project with constrained site logistics and limited laydown space.

Project Highlights

The Indigo Hotel and Apartments development stands out not only for its scale but for its storytelling and celebration of Auckland’s evolving identity.

• The hotel interiors creatively blend industrial elements with heritage materials such as exposed brick, reclaimed timber, and vintage automotive references.
• The modern tower’s guest rooms maintain a refined industrial feel, incorporating subtle local cultural references that connect guests to the heart of the city.
• The podium revitalizes Auckland’s historic entertainment district, contributing new life and energy to a growing cultural hub.

At KOROK, we are proud that our systems play a quiet but vital role in supporting developments like Indigo Hotel and Apartments — delivering life-safety, acoustic comfort, and buildability for landmark projects that help shape the future of our cities.

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CASE STUDY

90 Devonport Road

Pushing Boundaries with KOROK

At KOROK, we’re proud to have contributed to 90 Devonport Road—a pioneering project that now holds the title of New Zealand’s largest mass timber office building. Designed by Warren and Mahoney and developed by Willis Bond in partnership with Tauranga City Council, this landmark project redefines what’s possible for sustainable commercial construction in Aotearoa.

As part of the build, 78mm KOROK® fire and acoustic rated panels were specified and installed for external wall applications, contributing to the project’s high-performance envelope while supporting the mass timber structure with lightweight, resilient protection. Installed by Tika Interiors Limited, our panels were chosen for their proven reliability, fast installation time, and ability to support sustainable outcomes without compromising safety or acoustic control.

Sustainability at Scale

The goal was ambitious—a 100% reduction in embodied carbon, with a design targeting a 6 Star Green Star rating (the highest possible), alongside NABERSNZ and WELL Building Standard benchmarks. The result? A building that not only showcases natural beauty through its exposed timber columns and warm finishes, but one that’s genuinely future-ready.

By prioritising timber and selecting high-performance materials like KOROK®, the project team avoided designing in unnecessary complexity or carbon-intensive solutions. This thoughtful approach resulted in a cost-neutral, repeatable commercial model that leads the charge for the next generation of green buildings in New Zealand.

Building for People and Performance

Built by LT McGuinness, this 10,400sqm building now brings together the entire Tauranga City Council administration team under one roof for the first time since 2014. The space fosters collaboration, connection, and a shared commitment to a sustainable future.

“We wanted to push the boundaries to design a wholly sustainable, future-focused workplace which maximises the use of natural materials such as the exposed timber columns which celebrate the uniqueness of the building.”
— Anne Tolley, Chair of the Commission

KOROK’s Role

KOROK’s lightweight fire and acoustic rated wall systems have been engineered to complement mass timber construction by reducing structural loads, supporting acoustic separation, and accelerating installation programs. On a project of this size and vision, our 78mm panels provided the performance needed without compromising the environmental goals or design integrity.

As advocates for sustainable innovation in construction, we are proud to see our systems play a role in delivering landmark projects like 90 Devonport Road. It’s another example of how the KOROK system supports smarter, safer, and more sustainable buildings.

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CASE STUDY

The Glasshouse, Morningside

Glasshouse Morningside is a unique, urban oasis nestled in the heart of Auckland, offering a serene and elegant venue for a variety of events. As part of the evolving Morningside Precinct, Glasshouse contributes to the area’s dynamic and curated character, blending contemporary architecture with a mix of vibrant businesses. Designed to host everything from weddings and private parties to corporate functions and photoshoots, Glasshouse provides an unparalleled event space defined by its striking glass walls and lush greenery.

KOROK’s Role in the Project

To ensure the durability, safety, and acoustic integrity of this unique venue, 78mm KOROK panels were selected as the core external wall system solution. KOROK’s fire-rated and acoustic-rated panels played a crucial role in maintaining the building’s aesthetic while offering high-performance protection against fire, noise, and external weather conditions.

Key Features of KOROK External Wall Systems in Glasshouse Morningside

Fire-Rated & Weatherproof Protection

Glasshouse Morningside required external walls that met stringent fire safety requirements while also standing up to New Zealand’s diverse weather conditions. KOROK External Wall Systems provided a high-performing, fire-resistant solution that ensured both occupant safety and long-term durability.

Lightweight & Cost-Effective Installation

With no need for engineered slabs, KOROK’s lightweight panel system significantly reduced material costs and installation time. This efficiency enabled the construction team to maintain the project timeline without sacrificing quality or structural integrity.

Seamless Acoustic Performance

As a venue designed for events and gatherings, controlling sound was a crucial consideration. KOROK’s acoustic-rated panels ensured effective sound insulation, preventing noise disruptions and enhancing the intimate atmosphere of the space.

Durability Without Additional Cladding

Designed specifically for high-wind zones and exposed external applications, KOROK’s panels eliminated the need for extra cladding, reducing maintenance costs while maintaining a sleek architectural finish that complemented the venue’s glass-wall aesthetic.

Conclusion

The Glasshouse Morningside stands as a testament to the versatility and performance of KOROK External Wall Systems. By providing a lightweight, fire-resistant, and acoustically efficient solution, KOROK played an integral role in shaping this iconic Auckland venue. Our systems continue to set the standard for modern construction, offering architects and builders a practical yet high-performing solution for external wall applications.

For more information about our External Wall Systems and how KOROK can enhance your next project, visit our website or get in touch with our team today.

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When discussing construction techniques, one important aspect to consider is panel handling, which ensures safety and efficiency on site.

Panel Handling

KOROK manufactures lightweight wall panels consisting of galvanised or colour steel shells filled with aerated concrete.

Generally, KOROK products are delivered to your building or other site on long trailers and articulated trucks.

Our products are packed with reasonable protection against damage during delivery, however care must be exercised during unloading.

Forklift, Hiab or crane unload is required.

GUIDELINES

Ensure packs are lifted slowly, avoiding jerking where possible.

Forklift unloading – 150mm between pack and mast.

Ensure soft slings are neatly running on the inside of the two most inner timber collars of the pack.

Ensure soft slings are running continuously from the hooks to underneath the pack and back up to the hook.

Do not loop the sling around itself with only one end connected to the hook. This may damage the panels when lifted.

Ensure you lift only one or two packs at a time.

PACK SIZES

The panels are packed in timber pallets, measuring 1200mm wide by 300mm high.

There will be 2, 4 or 6 timber pallets for each pack (depending on length), nominally spaced 1200mm apart, middled from pack centre.

Packs can be stacked up to 6 packs high and must be placed side by side or end on end, on the truck / trailer tray.

When stacking back-to-back, timber collars must butt up against each other.

The length of the pack will vary according to the length of the panel required by the customer, commonly between 2.0 and 7.0 metres in length (can be up to 9.0m).

COMMON PACK WEIGHTS

Standard 3 metre pack = 390 – 470kg (nominal); Standard 6 metre pack = 780 – 936kg (nominal).

STRAPPING DOWN PACKS

Loads must be strapped down and secured by appropriate means. Load strops are most highly recommended, allowing 12 to 16 strops for a full semi load, more for B-Train transport.

Packs are to always be strapped over timber collars. No belly straps done with plastic angles at any time.

When stacking higher than 4 packs, a second set of straps must be placed after the third pack over timber collars only, before adding further packs.

ACCESSORIES

At times, a bundle of steel C-track or Angle strips may be placed on top of the load. These may measure up to 6.0 metres in length and weigh from 10kg to 500kg depending on the quantity.

IN TRANSIT

Where possible, avoid sudden braking and jolts during transit to reduce impacts on the product.

Re-tension strops every two hours at a minimum.

UNLOADING

Forklift, Hiab or crane unload is required.

Use soft slings or forks only, no chains to be used on product.

All lifting to only be done under middle crate, closest to the bearers to take the weight.

Forklift unloading – 150mm between pack and mast.

Care must be taken on unload and storage of product, avoiding bumps and scratching.

Guidelines must be carefully followed (turn over page).

At KOROK, we are committed to delivering the highest quality fire and acoustic rated wall systems, and today we are excited to introduce a major upgrade in our materials. We are transitioning to the new COLORSTEEL® MAXAM™, which will replace our previously used COLORSTEEL® ENDURA® and COLORSTEEL® MAXX® ranges. This change marks a significant advancement in the technology and performance of our wall systems.

What is COLORSTEEL® MAXAM™?

COLORSTEEL® MAXAM™ combines the renowned quality and consistency of COLORSTEEL® with innovative ACTIVATE™ technology. This new single substrate product solution is designed with corrosion resistance and longevity in mind, making it suitable for most of New Zealand’s environmental conditions.

The Benefits of ACTIVATE™ Technology

• Strategic Positioning: The aluminium/zinc/magnesium compounds in the coating are strategically positioned to activate at the start of weathering, providing sacrificial protection when it is most needed.
• Robust Barrier Formation: Magnesium compounds encourage the formation of a robust barrier at cuts and scratches, slowing the rate of subsequent corrosion.
• Long-Lasting Protection: The magnesium compounds ‘activate’ the metal coating, resulting in more effective, longer-lasting sacrificial protection.

Transitioning to the Future

The introduction of COLORSTEEL® MAXAM™ reflects our commitment to innovation and excellence. By integrating this advanced material into our KOROK wall systems, we are ensuring that our products not only meet but exceed the highest standards of performance and durability. For more information on COLORSTEEL® MAXAM™ and its benefits, please contact our customer service team.

Recent Articles

For over  25 years, KOROK has been a trusted provider of high-performance fire and acoustic walls for the multi-level construction market. Now, with the introduction of the KOROK KIR high-performance intertenancy apartment wall systems, KOROK offers comprehensive solutions for seamless floor plate transitions.

Our systems integrate lift cores, riser ducts, stair cores, hallways, and apartments into one streamlined package. Experience unparalleled fire, seismic, acoustic, and safety protection with KOROK – your all-in-one solution for modern construction needs.

Simplify with KOROK: Combining Performance and Safety

Experience the perfect blend of simplicity and performance with KOROK. Our range of IT wall solutions incorporates fire protection, seismic deflection, passive safety, and acoustic efficiency, all while eliminating complex build-ups. KOROK delivers unmatched performance, safety, and simplicity for your construction needs.

Intertenancy Apartment Solution

• Early Installation
• Solid & Secure
• Tested performance
• STC rating from 55 up to 69
• Fire rating from FRR 30 to FRR 120
• Simplified program continuity
• Waste reduction with custom lengths

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Wall Transition

• Tested Fire Door Solutions
• Simple transitioning for interface junctions

Corridor, Service Riser & Ducts

• Multiple wall design solutions
• Single-sided fix
• Simple passive fire service penetrations allowing for early services installation
• Programme Continuity
• Reduction in scaffolding
• Early Inspection & installation

Lift Cores

• Structural steel infills
• Intumescent coated steel connections
• Slab to Slab options
• Early fix services & lift components
• Added fall protection
• Simple penetration solutions
• Door head solutions
• Early installation & sequencing continuity

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Stair Core & Scissors Stairs

• Safe exit
• Linings are optional
• Prefinished colour coated panel options
• Prefinished panel provide a cost-effective, single fixed solution
• Reduced structural steel
• Multiple installation solutions
• Programme continuity
• Small crew to install
• Lightweight simplicity
• Handrail connection

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Products

CASE STUDY

Xtreme Zero Waste Recycling Center

KOROK Panels at Work in Raglan: Quieting the Glass Recycling Hub

We’ve just wrapped up a project at the Xtreme Zero Waste recycling center in Raglan, where we installed a “box” using our fire and acoustic panels around their glass recycling facility. The goal? To keep the noise down from the glass recycling process. The crew at Xtreme Zero Waste couldn’t be happier, saying, “The box looks awesome and works well.” It’s great to see our panels doing their job, making the space quieter and more comfortable for everyone involved. We’re stoked to have been part of this project and to see our panels making a difference right here in Raglan.

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