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.
KOROK is proud to have supplied the critical fire and acoustic wall systems for the Auckland Film Studio and Sound Stage project. Designed by Ignite Architects and built by Haydn & Rollett Construction, this facility sets a new standard in the New Zealand cinema industry.
Our 78mm KOROK panels Gen 2 were chosen for their superior fire and sound-rated properties, achieving a Noise Criterion rating below NC-20. This was crucial in ensuring optimal recording conditions, despite the studios’ proximity to urban noise sources like Auckland’s western rail line.
Sustainable Design and Construction
The project has been awarded a 4 Green Star As-Built rating, recognizing its sustainable design and construction practices.
KOROK is honoured to contribute to a project that not only pushes the boundaries of film studio design but also promotes sustainability and economic growth in Auckland. We look forward to seeing the long-term benefits this project will bring to the local community and the entertainment industry.
High-Performing and Lightweight Panels for Superior Building Solutions
The 78mm KOROK® panels are engineered to provide exceptional performance in both fire and acoustic applications. These panels are roll-formed from high-quality COLORSTEEL® steel strips, with the steel conforming to the rigorous AS/NZS1397:2001 standard.
The combination of steel shells and an aerated concrete core ensures outstanding durability and functionality. Weighing approximately 10.2kg per lineal metre, these panels offer a lightweight solution that does not compromise on strength or safety.
Applications of 78mm KOROK® Colour Panels
Our 78mm KOROK® colour panels are versatile and suitable for various building applications, including:
KOROK® External Wall Systems: Ensuring robust protection with excellent thermal, acoustic, and fire-rated properties.
Lightweight Construction: Simplifies installation and reduces structural load requirements.
Durability: Engineered to withstand demanding conditions.
Efficiency: Panels are pre-finished and easy to install, reducing construction time and costs.
Transition to COLORSTEEL® MAXAM™
In our commitment to innovation and sustainability, we are transitioning to the advanced COLORSTEEL® MAXAM™, replacing the previous COLORSTEEL® ENDURA® and COLORSTEEL® MAXX® ranges. This transition represents a significant technological advancement, enhancing the performance and longevity of our wall systems. COLORSTEEL® MAXAM™ is designed to offer superior resistance to New Zealand’s diverse environmental conditions, making it an ideal choice for a wide range of applications.
All-in-One Fire & Acoustic Solutions for Boundary and External Walls
KOROK® External Wall Systems are non-loadbearing, fire- and acoustically-rated vertical wall systems combining a zinc-coated steel outer shell with a 400kg/m³ aerated concrete core. BRANZ appraised and designed for New Zealand conditions, they provide durable, high-performance external and boundary wall solutions for commercial and industrial buildings.
Delivering fire rating, acoustic separation, and weather-tight performance in a single integrated assembly, the lightweight system enables faster installation, reduces structural demand, and can eliminate the need for specially engineered slabs on many projects. Available in single-skin or over-clad configurations, the systems are engineered to perform under defined design wind pressures.
How the System Works
The system uses 78mm interlocking panels with a 250mm effective cover width, installed vertically to form a continuous fire- and acoustically-rated barrier. The interlocking geometry limits acoustic leakage while maintaining fire-resisting continuity. The steel shell provides durability and weather protection, and the concrete core delivers inherent fire resistance and acoustic mass. Five system configurations are available:
EX1 – 78mm COLORSTEEL® panel, single-skin system
EX2 – 78mm COLORSTEEL® panel with internal fire-rated lining
EX3 – 78mm panel with engineered over-clad metal system
EX4 / EX5 – Over-clad systems incorporating internal fire-rated lining
All systems provide two-way fire resistance and are designed as vertical in-fill wall systems fixed to supporting primary structures.
External Wall System Engineered for Commercial and Industrial Applications
KOROK® External Wall Systems are suitable for warehouses, factories, sheds, cinemas, lift shafts, and other commercial applications where fire separation and acoustic control are critical.
EX1 and EX2 systems are appraised as single-skin, non-loadbearing, fire- and acoustically-rated external walls. EX3, EX4 and EX5 systems incorporate drained and vented cavity cladding systems and are subject to project-specific engineering design. The systems are designed for defined wind pressures and vertical span limits, ensuring controlled structural behaviour under service and ultimate limit state conditions.
Code Compliance Highlights
Clause B1 – Structure: Designed for self-weight, wind, earthquake, impact, creep and shrinkage in accordance with AS/NZS 1170.
Clause B2 – Durability: Designed to achieve 15-year and 5-year durability performance requirements, subject to environmental exposure category.
Clause C3 – Fire Affecting Areas Beyond the Fire Source: Provides passive fire separation to limit fire spread.
Clause C6 – Structural Stability: Requires supporting primary elements to achieve equivalent fire resistance where applicable.
Clause E2 – External Moisture: Designed to meet external moisture performance requirements.
Clause F2 – Hazardous Building Materials: Does not present a health hazard in service.
Key Performance Ratings
Fire Resistance Rating (2-Way): Up to –/240/240 minutes, depending on system configuration.
Choose from a full range of COLORSTEEL® options to match your project’s external design. Explore our CAD Library for DWG files related to KOROK® External Wall Systems. Access detailed KOROK® External Systems Literature for specifications, installation guides, and more. If you have any questions or need further assistance, contact us for more information.
Durability and Service Life
Service life performance depends on environmental exposure category. COLORSTEEL® MAXAM™ external shells provide up to 25 years resistance to perforation in defined NZS 3604 zones, with paint finish durability of 15 years under normal conditions. Panels are intended to remain rain-washed and fully exposed. Geothermal environments require consultation with the relevant Building Consent Authority.
The internal side lined with 1 layer 19mm GIB Fyreline® or acceptable GIB® alternatives or 2 layers 10mm GIB Fyreline® or acceptable GIB® alternatives.
Longrun profiled steel cladding system as selected.
The internal side lined with 1 layer 19mm GIB Fyreline® or acceptable GIB® alternatives or 2 layers 10mm GIB Fyreline® or acceptable GIB® alternatives. Longrun profiled steel cladding system as selected
1 layer 10mm GIB® Standard plasterboard or equivalent each side
Acoustic insulation must be either Autex GreenStuf SW90 or Pink Batts R 2.2 each side.
KOROK® metal fire flashing is installed to the top C-track.
KOROK® metal KIT flashing is installed to horizontal joints.
90mm steel or timber frame each side
86mm overall. Framing not to touch KOROK® panel or fire flashing
KOROK® metal fire flashing is installed to the top C-track. KOROK® metal KIT flashing is installed to horizontal joints.
1 layer 10mm GIB® Standard plasterboard or equivalent each side
Acoustic insulation must be either Autex GreenStuf SW90 or Pink Batts R 2.2 each side.
KOROK® metal fire flashing is installed to the top C-track.
KOROK® metal KIT flashing is installed to horizontal joints.
90mm steel or timber frame each side
80mm overall. Framing not to touch KOROK® panel or fire flashing
KOROK® metal fire flashing is installed to the top C-track. KOROK® metal KIT flashing is installed to horizontal joints.
KOROK® metal fire flashing is installed to the top C-track OR 13 mm GIB Fyreline® or equivalent x 120 mm strip with sealant is fixed at 250 mm centres top and bottom, using 6g x 32 mm drywall screws.
