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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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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Sound Solutions for Loud Workspaces: How KOROK Panels Tame Machinery Noise

When machinery is operating at high intensity, the noise can be just as intense as the output. Whether it’s recycling, manufacturing, or any high-impact industrial process, managing sound is not just a comfort issue – it’s a health, safety, and productivity one.

At KOROK, we understand the challenges that come with acoustic performances. That’s why our fire and acoustic wall systems are engineered to offer more than just compliance – they’re built to perform under pressure, especially when sound control is critical.

Real-World Results in Raglan: Xtreme Zero Waste

A great example of this in action is our recent project at the Xtreme Zero Waste Recycling Center in Raglan.

The challenge? Containing the loud crashes and clinks from their glass recycling facility – an essential part of their operation, but not the easiest on the ears.

Our solution was simple but effective: construct a purpose-built enclosure using KOROK fire and acoustic panels – essentially a “box” that wrapped around the recycling machinery to absorb and block the sound.

The result? Immediate improvement.

“The box looks awesome and works well,” the Xtreme team told us. It’s now a noticeably quieter and more comfortable environment for staff and visitors alike.

Why KOROK Panels Work for Noisy Machinery

KOROK wall systems are purpose-built for industrial environments, offering high acoustic performance to reduce machinery noise, along with fire resistance for added safety. Their durable construction ensures reliable performance under pressure, while the modular design allows for tailored solutions—from full enclosures to partitions. Plus, they deliver a clean, professional look, as demonstrated in real-world applications like Raglan.

For facilities like Xtreme Zero Waste, acoustic control isn’t just a luxury – it’s essential to keep workers safe, comply with council noise regulations, and maintain good relationships with surrounding communities.  So, if you’re facing excessive noise from machinery, get in touch. We’ll help you design a system that keeps the sound where it belongs – inside the box.

Interested in acoustic solutions for your facility?

KOROK Systems for Aged Care & Retirement Projects

As New Zealand’s population ages, demand is growing for retirement and aged care facilities that deliver comfort, safety, and peace of mind. That’s where KOROK® Fire and Acoustic Rated Wall Systems come in – designed to meet the unique demands of healthcare and retirement village construction.

Why KOROK is a Smart Choice for Retirement Living:

See KOROK in Action

Metlifecare Gulf Rise – Red Beach, Auckland

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

• Read the Case Study →

Summerset St John’s – Auckland

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.

• Read the Case Study →

Ready to future-proof your next retirement project?
Get in touch with our team for system recommendations, CAD files, and technical support.

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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High-Performance Healthcare Environments are crucial in modern medical facilities, aiming to improve patient outcomes and efficiency.

Smart Wall Solutions for High-Performance Healthcare Environments

KOROK: There’s No Substitute for Tested Performance

Fire & Acoustic Wall Systems Trusted in Healthcare. KOROK® is a proven fire and acoustic wall system that delivers key performance benefits for healthcare construction. Hospitals demand the highest standards in safety, acoustic control, compliance and speed of delivery. KOROK delivers – with BRANZ-appraised, tested systems that are already trusted in hospitals, corridors, IT rooms, service risers, lift shafts, and more

Engineered for IL3/IL4 Resilience: Seismic Performance and Rapid Remediation Design

As the ultimate All-in-One solution for fire & acoustic-rated wall systems, KOROK® panels offer unmatched performance for high-importance structures. With strong seismic performance and the ability to withstand high drift limits, KOROK® panels are ideal for IL3 and IL4 buildings, such as hospitals, emergency response centres, and essential utilities. By undertaking this seismic testing, KOROK® reinforces its commitment to superior building resilience, helping to minimize damage, lower repair costs, and maintain operational continuity after earthquakes.

Core Benefits That Deliver Certainty in Fire, Acoustic, Seismic, and Programme Performance

All-in-one Solution for all Fire and Acoustic Rated Walls, Engineered for Complex Healthcare Builds

One system, multiple applications. From intertenancy walls to lift shafts, risers, ducts and corridors. KOROK panels provide comprehensive protection throughout your entire project.

LIFT SHAFTS

SERVICE RISERS & DUCTS

CORRIDORS & HALLWAYS

INTERTENANCY WALLS

STAIRCASE & ESCAPE PATHS

PLANT ROOMS & IT ROOMS

Save Time. Save Labour. Reduce Risk.

Need more info or want to present this to a client? We can help

At KOROK, we know that healthcare projects are high-stakes environments, with no room for delays, compliance issues, or uncertainty. That’s why we offer KOROK 360, a full-circle support package developed to give you confidence from concept to completion. Whether you’re in early-stage design or managing construction on site, KOROK 360 provides targeted, hands-on support tailored to your needs

Ready to Spec KOROK?

Let’s lock it in, and get your project moving with tested, proven performance. Whether you’re working on early-stage design, refining your specification, or needing trusted fire and acoustic systems that meet healthcare demands – we’re here to help. Get expert guidance, fast documentation, and the confidence that comes from working with systems already trusted in hospitals across New Zealand.

Talk to us today and bring KOROK certainty to your next healthcare build.

Paul Carrigan
Specification Manager
📧 paul@korok.com | 📞 0800 KOROK NZ

Andrew Hawkins
Specification Manager
📧 andrew@korok.com | 📞 0800 KOROK NZ

KOROK Noise Control Systems: Additional Acoustic Solutions

Advanced Noise Control Solutions for Targeted Acoustic Performance

KOROK Building Systems introduces new range of acoustic solutions to tackle specific sound challenges in modern construction. These innovations build on KOROK’s already extensive portfolio of proven acoustic systems.

Key Applications:

• Cinemas: Immersive audio experiences without disruptive sound bleed.
• Terrace Housing: Quieter, more comfortable living environments.
• Commercial Spaces: Improved sound management for offices, hospitality, and more.

Book a Free Presentation and see firsthand how KOROK’s Building Systems can benefit your project.

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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