Fire & Acoustic Solutions for Residential Design

Designing townhouses, apartments, and terraced housing is always a balancing act. On one hand, you need to ensure absolute compliance with fire and acoustic separation standards. On the other, you’re under pressure to keep the build practical, efficient, and cost-effective. The systems you specify can either make that process seamless – or create unnecessary challenges. That’s why more architects are turning to KOROK® Fire and Acoustic Wall Systems

Why Architects Choose KOROK® in Residential Projects

Confidence in fire and acoustic performance is at the heart of KOROK®. Every system has been thoroughly tested, BRANZ-appraised, and designed to meet New Zealand’s strict compliance requirements. For residential projects, this reliability gives peace of mind – whether you’re working on attached homes or a multi-level apartment complex.

Equally important is speed. KOROK® panels are lightweight, pre-finished, and engineered with a steel shell and aerated concrete core. This reduces the need for multiple linings and accelerates installation, keeping builds moving forward and helping architects see their designs realised without compromise.

KOROK® also makes detailing simpler. The systems are straightforward and practical, allowing you to integrate fire and acoustic separation into your plans without excessive complexity. This ease of design translates into fewer site issues, ensuring a smoother construction process overall.

And then there’s sustainability. With panels that can be reused across projects, KOROK® helps reduce construction waste throughout the building lifecycle. For architects working to meet client expectations and growing environmental standards, this makes it a solution that balances performance with responsibility.

Designed for Residential Intertenancy

From terraced housing to multi-level apartments, KOROK® Intertenancy Systems are designed to integrate seamlessly into residential projects. They provide the reliable fire and acoustic separation you need, while also reducing time spent on problem-solving during construction.

Supporting Architects Beyond the Build

KOROK® goes further than supplying systems. Through CPD-accredited presentations, we provide architects and specifiers with practical knowledge that can be applied directly to projects – all while earning valuable CPD points. It’s one more way we support your professional growth alongside delivering building solutions.

CASE STUDY

Te Iwitahi – Whangārei Civic Centre

The Project

The Te Iwitahi – Whangārei Civic Centre was conceived as a gateway project for Whangārei, reflecting multicultural themes, Tikanga Māori, and a transparent form to embody democracy in action. The four-storey building centralises council services, bringing together community, customer-facing functions, and staff workplaces in a single hub.

With a design anchored by a striking light-filled atrium, flexible open-plan workspaces, and biophilic design principles, the Civic Centre has become a vibrant, welcoming environment for both staff and community.

KOROK is proud to have supplied our fire and acoustic-rated wall systems to a project that has already achieved national recognition and set a benchmark for civic architecture in New Zealand.

KOROK’s Role

KOROK was proud to contribute to this award-winning project by supplying over 500m² of our fire and acoustic-rated wall panels. Our systems were installed across all lift shafts, risers, and ducts, delivering the critical fire safety and noise control performance the building required. These elements are essential in large civic projects, where high volumes of staff and community members move through the building daily. By providing a lightweight, robust, and compliant wall system, KOROK helped ensure safety, comfort, and efficiency throughout the construction process.

The Outcome

The Whangārei Civic Centre is now recognised not only for its architectural excellence but also for the way it serves the community. For KOROK, being part of such a landmark civic development showcases the reliability of our systems in high-performance, large-scale projects. Our involvement demonstrates how KOROK panels provide trusted solutions for critical infrastructure, meeting stringent fire and acoustic requirements while supporting project efficiency.

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CASE STUDY

30 Madden Street, Multi-Unit Residential

Located in Auckland’s Wynyard Quarter, 30 Madden represents the latest chapter in one of New Zealand’s largest urban regeneration projects. Developed by Willis Bond and designed by Studio Pacific Architecture, this multi-stage residential development features over 150 apartments, townhouses and duplexes across five buildings.

With sustainability and liveability at its core, 30 Madden achieved a 7-Star Homestar rating and received accolades including a Gold Pin at the 2022 Best Design Awards and an Excellence Award at the 2022 NZ Property Industry Awards. Behind the scenes, KOROK® played a key role in delivering high-performance intertenancy wall systems that supported both the environmental and construction goals of the project.

KOROK’s Contribution

To meet the stringent fire and acoustic performance requirements of multi-residential buildings, KOROK® supplied our 78mm Galv Panels for use in all intertenancy residential walls across the 30 Madden development. In multilevel buildings like apartments, intertenancy walls must achieve excellent fire resistance and sound insulation – while also fitting into tight construction programs. Traditional framed systems often rely on linings that complicate detailing, especially in ceiling plenums. KOROK® Intertenancy Residential (KIR) Wall Systems offer a smarter alternative:

• No ceiling plenum linings required
• Outstanding fire and acoustic performance
• Streamlined design and faster installation
• Less material waste and reduced cost

Our KOROK® 78mm Galv Panels are roll-formed from zinc-coated steel and filled with a proprietary aerated concrete core. Each panel weighs only 10.2 kg per lineal metre, making them a lightweight yet high-performing solution that’s well-suited to modern mid- and high-rise developments like 30 Madden.

A System That Supports Award-Winning Design

With high-end finishing, elevated community spaces, and sustainable features such as stormwater harvesting and native landscaping, 30 Madden stands as a showcase of future-focused urban living. KOROK’s contribution ensured that behind the architectural elegance lies robust fire and acoustic protection – providing peace of mind to residents and long-term performance for the building.

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CASE STUDY

New Zealand International Convention Centre (NZICC)

The New Zealand International Convention Centre (NZICC) sets a bold new standard for large-scale civic infrastructure. Located in the heart of Auckland and occupying half a city block, the NZICC is not just a building, it’s a redefinition of what it means to host the world in a uniquely New Zealand way. KOROK is proud to have played a vital role in supporting the success of this landmark project through the supply of our fire and acoustic rated systems.

Designed by Warren and Mahoney in collaboration with Moller Architects and Woods Bagot, and built by Fletcher Building, the NZICC features a vertical stacking layout and an extensive program of flexible, high-performance spaces. With a 2,850-seat plenary hall, over 8,000 square metres of exhibition space, and a dedicated multi-use theatre, the structure demanded robust and adaptable building solutions at every level.

KOROK® Systems: Protecting the Heart of the Building

KOROK supplied our fire and acoustic rated wall systems for all lift shafts, risers, and duct enclosures throughout the NZICC. In a facility of this scale and complexity, these core services are central to both life safety and operational efficiency. Our systems delivered key advantages to the project team, helping them stay on schedule while maintaining the highest standards of safety and performance:

• Single-side installation meant that lift shafts could be enclosed without the need for internal scaffolding—eliminating logistical complications and reducing time on site.
• Superior fire and acoustic performance provided assurance in both regulatory compliance and end-user comfort. In a convention centre where large crowds and simultaneous events are the norm, effective noise separation and passive fire protection are non-negotiable.

Building for the Future

As the NZICC moves toward completion at the end of 2024, it will stand as a global benchmark for hospitality and cultural expression—featuring expansive glass façades, stunning Māori and New Zealand landscape-inspired artwork, and a new pedestrian laneway that connects people across the city.

We’re proud that KOROK systems contributed to the delivery of a project that not only transforms its urban surroundings but also brings safety, performance, and durability to the heart of one of New Zealand’s most significant public venues.

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CASE STUDY

Metlifecare Gulf Rise

Metlifecare Gulf Rise in Red Beach is a standout example of modern retirement living — open, connected, and community-focused. With architectural input from Warren and Mahoney (Stage 1), Ignite Architects (Stages 1–4 of Precinct Two), and landscape design by Boffa Miskell, the project is a masterclass in designing for wellbeing and longevity.

KOROK proudly supplied our fire and acoustic wall systems throughout the development, helping deliver on the vision of safe, peaceful, and efficient living for older New Zealanders

Why KOROK is a Smart Choice for Retirement Villages

Retirement living comes with specific design and performance requirements – safety, acoustic comfort, fast build times, and minimal disruption. KOROK delivers on all fronts:

• Superior acoustic separation – essential for resident privacy
• Fire-rated protection – compliant and reliable for high-risk occupancies
• Quick, clean installation – ideal for staged builds and live sites
• Low-waste, lightweight system – supporting site safety and sustainability

Whether in intertenancy walls, lift shafts, or service corridors, our systems helped the Gulf Rise team maintain build speed, reduce on-site disruption, and meet NZBC requirements with confidence. Gulf Rise is a bold, forward-thinking village — and we’re proud our systems helped make it a safe, quiet, and welcoming place to call home.

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CASE STUDY

Summerset St John’s Retirement Village

Summerset St John’s Retirement Village represents the pinnacle of modern retirement living—where luxury, location, and lifestyle converge. Set in Auckland’s eastern suburbs with sweeping views and proximity to beaches, cafes, golf clubs, and key amenities, it offers an unmatched standard of comfort and care.

KOROK is proud to have played a vital role in ensuring the safety, acoustic comfort, and performance of this flagship development by supplying our fire and acoustic rated wall systems across key areas of the project.

Why KOROK Was Chosen

Summerset’s vision for St John’s included high-rise apartment living with resort-style amenities and a continuum of care offering. This meant acoustic privacy and fire safety were non-negotiable—especially in a multi-level setting with diverse accommodation types, from premium apartments to memory care suites.

Our systems were chosen for their:

• Proven fire resistance across intertenancy, service risers, lift shafts, and stairwells.
• Superior acoustic performance, critical for resident comfort and privacy.
• Lightweight yet robust construction, ensuring ease of installation while supporting the structural design and seismic requirements of the buildings.

KOROK’s solution allowed Summerset to meet stringent compliance demands while achieving the architectural and operational goals of the project.

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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

Catalina Bay Apartments

KOROK® Fire and Acoustic Wall Systems at Catalina Bay Apartments

KOROK Building Systems played a key role in the construction of the Catalina Bay Apartments in Auckland, supplying our high-performance fire and acoustic wall systems. This 13-level waterfront development, built by LT McGuinness for client Willis Bond, consists of 73 luxury apartments across two towers and nine townhouses on a concrete podium. Designed by Architectus, the project integrates sustainability, history, and high-end living, offering panoramic views of Waitemata Harbour.

A Landmark Development with a Strong Foundation

The Catalina Bay Apartments were built on a historically significant site, once home to a Royal New Zealand Air Force base. The design of the development pays homage to this heritage while providing modern, high-quality residences.

Despite construction challenges such as extreme weather events and pandemic-related delays, the project was successfully completed in July 2024, thanks to the collaborative efforts of the client, consultants, and contractors. More than 2,200 workers contributed to this impressive 28-month build.

KOROK® – Setting the Standard in Fire and Acoustic Protection

KOROK is proud to have contributed to this landmark residential development, providing solutions that ensure safety, comfort, and efficiency. Our fire and acoustic wall systems continue to set the benchmark for high-performance construction in New Zealand’s premium apartment projects.

KOROK supplied all fire and acoustic wall systems for the project, including:

• Lift Shafts, Risers, and Ducts
• Intertenancy Apartment Walls

Our systems were chosen to enhance fire safety, acoustic insulation, and construction efficiency in this high-end residential development.

KOROK® for Lift Shafts, Risers, and Ducts

KOROK® panels provided an efficient and robust solution for the lift shafts, risers, and ducts at Catalina Bay, offering multiple advantages:

• Single-side installation: Eliminates the need for scaffolding inside shafts, accelerating the build process.
• Superior fire and acoustic performance: Ensuring compliance with New Zealand’s strict building codes for safety and comfort.

KOROK® for Intertenancy Apartment Walls

Each apartment in Catalina Bay was designed for privacy and luxury. KOROK® intertenancy walls played a crucial role in achieving this by delivering:

• Proven fire-rated protection and acoustic insulation, ensuring a safe and peaceful living environment.
• Solid wall construction, enhancing security and long-term durability.
• Faster installation times, reducing project timelines and labor costs.
• Sustainable solutions, minimizing construction waste and contributing to the development’s Homestar-7 sustainability rating.

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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).

Introducing COLORSTEEL® MAXAM™: The Next Generation of Steel Solutions

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.

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