Project Overview

The City Rail Link (CRL) is the largest transport infrastructure project ever undertaken in New Zealand, transforming Auckland’s rail network into a modern rapid transit system. This landmark development creates New Zealand’s first fully underground railway line, increasing network capacity by 50% and connecting key city precincts through a world-class transport system designed to serve Auckland’s growing population for generations to come.

The Challenge

Major underground rail infrastructure projects present unique fire protection challenges. Service risers, ducts, ceiling spaces, and bulkheads must maintain fire compartmentation throughout the network while allowing efficient installation within constrained construction environments.

The CRL project required solutions that could:

• Provide reliable fire and acoustic performance across critical building services infrastructure.
• Support complex construction sequencing within a large-scale infrastructure project.
• Minimise installation time in difficult-to-access locations.
• Reduce disruption to other trades working simultaneously on site.
• Deliver consistent fire continuity throughout service-rich environments.

KOROK® Solution

KOROK® supplied 760m² of its 78mm KOROK Galv Panels for use across risers, ducts, ceilings, and bulkheads throughout the project. Installed by Livefirm Construction, the KOROK® systems provided a lightweight, high-performance fire-rated solution tailored to the demanding conditions of underground rail infrastructure construction.

Project Benefits

By implementing KOROK® systems throughout selected riser, duct, ceiling, and bulkhead applications, the project benefited from:

• Fast installation using lightweight prefabricated panels.
• Single-side construction for risers and ducts, eliminating the need for internal scaffold access.
• Reliable fire compartmentation for critical infrastructure environments.
• High acoustic performance within service areas.
• Reduced site complexity and improved coordination with other trades.
• Efficient construction sequencing in restricted-access underground spaces.
• Proven performance on one of New Zealand’s most complex infrastructure projects.

Supporting a Landmark Infrastructure Project

The City Rail Link represents a transformational investment in Auckland’s future, delivering enhanced connectivity, reduced travel times, and increased public transport capacity for generations to come. KOROK® was proud to contribute to this nationally significant project, providing fire-rated solutions that supported efficient construction while helping maintain the high safety and performance standards required for critical transport infrastructure.

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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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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 Ravenscroft Fire and Smoke Damper has been carefully engineered to seamlessly integrate with high performance KOROK wall systems. Preventing the spread of both fire and smoke between building compartments, preserving the barriers integrity for up-to two hours.

The Ravenscroft Fire Damper for KOROK is a combined balancing and fire damper. The damper can easily be tested and preset with the indicator handle from outside the duct. Duct access panels are not required. The Ravenscroft Smoke/Fire Damper for KOROK is a combined fire and smoke damper. The damper can easily be tested by pressing the centre of the thermo-electric tripping device. Flexible ductwork connectors must be used to separate rigid ducting from the damper. These prevent excess force being transferred to the wall mounting in the advent of ductwork deformation or collapse during a fire or earthquake.

Available sizes

125 | 150 | 175 | 200 | 250 | 300 | 400mm (125 and 175 available by request)

Recent Articles

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.

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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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